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post #1 of 43 Old 02-22-2017, 06:30 PM Thread Starter
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WJ Driveshaft Information Page


Preface:
With so many driveshaft questions that have popped up on this WJ forum, I felt the notion to create this FAQ page so that as much information is consolidated into one place. My goal of this is to help others and provide as much unambiguity about driveshaft conversions and servicing as possible.

This document may be edited at any time to update information

Thank you to the following who were kind enough to share their knowledge, information and tips to help me create this page
:

@ChrisHager
@skain8






Table of Contents :

Section 1 - Determining What Driveshaft is Currently Installed

Section 2 - Parts Needed for Conversions
2.1) Rzeppa/Rzeppa -> Double Cardan
2.2) Rzeppa/Fixed Yoke -> Double Cardan
Section 3 - Double Cardan Driveshaft Swap Options
3.1) Manufacturers
3.2) WJ and Non-WJ Jeeps Driveshaft Information
Section 4 - Double Cardan Swap Write-Ups
4.1) Chris Hager’s Rzeppa/Fixed Yoke -> Double Cardan Conversion
4.2) JGC99’s Rzeppa/Rzeppa -> Double Cardan Conversion (Specific information on the front D30)
Section 5 - Servicing Rzeppa Joints and U-Joints
5.1) YouTube video on replacing Rzeppa Joints and UJoints
5.2) YouTube video on installing the Rzeppa and Double Cardan Driveshafts



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post #2 of 43 Old 02-22-2017, 06:31 PM Thread Starter
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Section 1 - Determining What DriveShaft is Currently Installed




The first step in this process is determining what driveshaft is currently installed on the jeep (shown below).


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There are three common driveshafts of the four shown that come with our WJs. They are: Rzeppa-Rzeppa, Conventional Double Cardan, and Rzeppa-Fixed Yoke. Finding out which one is installed is crucial for the next sections. Shown below is a very simple drive shaft decision tree for the different drive shafts (the chart was intended for broken Rzeppa joints).


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Looking at the chart and depending on what driveshaft you have, you might have questions on why the decisions are chosen. As said, this decision tree is primarily for those who have Rzeppa joints since those are the most frequently brought up topics. Those already with a Double Cardan joint would have no reason to try to convert to a Rzeppa joint. If a vehicle is lifted, the Rzeppa joints have shown that they do not like the increased angles associated with them (even on 2 lifts). The correlation being the higher the lift, the greater the angle on the driveshaft, the shortened life of the Rzeppa joint. So for lifted vehicles it is almost a requirement that you install a Double Cardan joint as it is more durable and lasts longer than a Rzeppa joint at the same angle with the lift kit installed. Your relationship with Rzeppa joints ended as soon as you set your jeep down with the lift kit installed. For those who have the Rzeppa joint at stock height, it is optimum to keep the Rzeppa joint as they have shown to be fine on stock angles and can provide you with a smoother driveline. Though you can switch to a DC, again, it is optimum to keep the CV joint.

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post #3 of 43 Old 02-22-2017, 06:31 PM Thread Starter
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Section 2 - Parts Needed For Conversions




2.1) Rzeppa/Rzeppa -> Double Cardan

Here is a full write-up on the front Dana30 yoke swap which will include all the tools and parts you need (special thanks to @JGC99 for this write-up): https://www.jeepforum.com/forum/f310/...te-up-1467249/

  1. Double Cardan Shaft
  2. Transfer case front output yoke
  3. Front axle D30 yoke
  4. May need new transfer case seal
  5. May need new pinion seal for the D30
  6. May want new washer and nut for pinion shaft




2.1) Rzeppa/Fixed Yoke -> Double Cardan

  1. Double Cardan Shaft
  2. Transfer case front output yoke
  3. May need new transfer case seal


***NOTE*** : New seals should be able to be sourced from your nearest auto parts retailers (Autozone, Napa, O’Reilly’s, Advanced Auto Parts, RockAuto.com, Federated Auto Parts, et. al.)


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post #4 of 43 Old 02-22-2017, 06:32 PM Thread Starter
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Section 3 - Double Cardan Swap Options




3.1) Manufacturers

  • Junk yards and Pick 'N Pulls : A great place to search local inventories is here -> http://www.car-part.com/
  • IRO (Iron Rock Offroad)
  • Carolina Driveline
  • Tom Woods
  • Custom built from local driveline shop
  • Rusty's Front Driveshaft Conversion




3.2) WJ and Non-WJ Jeeps Driveshaft Information

This is a list of information on WJs and non-WJ driveshafts; please note that most of them are significantly shorter than WJ drive shaft lengths. If you choose to go this route, please take measurements and consult your driveline specialist on where to go further. Also noting that the transfer case front output yokes are different from WJs and older model Jeeps (i.e. XJs and ZJs). You will need the front transfer case output yoke that is associated with the WJs that had the double cardan joint. Failure to do so risks transfer case fluid leaking at the yoke.

Here is a video comparing the WJ front transfer case output yoke vs a different yoke off of a different jeep:


Specifically you want this one (32 spline) :
wj_front_transfer_case_output_yoke.jpg



(Thank you @DaveRous , @yrkoverland and @Virmagicus for providing this information)

Quote:
Originally Posted by DaveRous View Post
XJ 87/88 2.5 Automatic 27.950 53003912
XJ 89/93 2.5 Automatic 27.970 53005540
XJ 89/01 2.5 Manual 25.310 53005541
XJ 89/01 4.0 Automatic 30.660 53005542
XJ 89/01 4.0 Manual 29.250 53005543
XJ 89/00 4.0 Manual 27.080 Export 53005544
XJ 89/00 4.0 Automatic 28.620 Export 53005545
XJ 87/88 4.0 Automatic Export 53005260
XJ 95/01 Diesel 27.640 Export 52098208

ZJ 1993 4.0 Automatic 30.530 52098341
ZJ 93/95 5.2 Automatic 32.870 w/o CV 53008427
ZJ 94/95 5.2 A500 30.625 w/o CV 52087805
ZJ 94/95 4.0 A500 w/o CV 52098790
ZJ 93/96 4.0 Manual 52098344
ZJ 93/96 4.0, 5.2 31.875 w/ 231, 242 52087805
ZJ 93/95 4.0 Manual 30.000 w/231 52088090
ZJ 93/96 5.2 33.000 w/ 231 53008427
ZJ 96/98 5.2, 5.9 31.250 w/ 249 & Model 30 52098379
ZJ 1996 5.2 Automatic 32.875 w/ 249 & Model 30 52098501
ZJ 96/98 4.0 33.000 w/ 242 52098707
ZJ 96/97 4.0 Automatic 31.250 52098850
ZJ 1996 5.2 Automatic 30.750 w/ 249 & Model 30 52099246
ZJ 96/98 4.0 33.500 w/ 249 52099260
Quote:
Originally Posted by yrkoverland View Post
Some WJ stuff:
These are compressed lengths based on this:
** Regarding Collapsed Length - The "U-Joint" type the measurement is from the center of the U-Joint to center of U-Joint. On flanged shafts, the measurement is from the outside of the flange.

WJ 99/00 4.0 34.625 52099497AD
WJ 99/00 4.7 33.250 52099498AD
WJ 01/04 4.0 34.625 52105884AA *
WJ 02/04 4.7 32.000 CV 52853500AB *

And some wrangler stuff:

CJ 80 2.5 Automatic 32.680 J5360985
CJ 81 2.5 Automatic 30.250 J5356501
CJ 80/81 2.5 SR4 31.750 J5360982
CJ 82/83 2.5 T176,T177 27.250 J5362815
CJ 83/86 2.5 T4, T5 29.500 J5360986
CJ 79 4.2 T150 26.500 3 Speed J5356500
CJ 79 4.2 T18 30.250 4 Speed J5356501
CJ 79 4.2 Auto 37.000 J5359382
CJ 80/86 4.2 Auto 32.680 J5360985
CJ 80/81 4.2 SR4, T4, T5 31.750 J5360982
CJ 81/86 4.2 T176, T177 29.500 J5360986
CJ 80/81 5.0 T176, T177 29.500 J5360986
CJ 81/86 5.0 Automatic 32.680 J5360985

YJ 87/95 2.5 38.000 53004369
YJ 87/95 4.2, 4.0 Manual 53002001
YJ 87/95 4.2, 4.0 Automatic 38.000 53004369

TJ 97/02 2.5 37.950 52098378AC
TJ 97/06 4.0 Manual 39.490 52098377AE
TJ 97/02 4.0 Automatic 52098378AC
TJ 03/06 2.4 Manual 52853402AB *
TJ 03/04 2.4 Automatic 52853401AB *
TJ 03/05 4.0 w/ 4.1 Rock-Trac 52853404AA *
Quote:
Originally Posted by Virmagicus View Post
Here's some good info...from Dana http://www2.dana.com/pdf/J321-CV.pdf

1997-98 GRAND CHEROKEE--------- *Location* *Spicer#* *Part#* *Length*
1310 Series, 4.0L Engine Auto trans. TC to FA 919376-1806* 52098707 31.750
242 TC Dana model 30 Front

1996-98 GRAND CHEROKEE
1310 Series, 5.2L, 5.9L Engine Auto. TC to FA 919376-1601* 56022666AA 29.600
trans., 249 TC Dana model 30 Front Axle

1996 1/2-97 GRAND CHEROKEE
1310 Series, 4.0L Engine Auto trans., TC to FA 919649-1412 52099260 31.530
249 TC Dana model 30 Front Axle
1310 Series, 2.5 L Engine, Manual TC to FA 919373-1510 52098706 29.020
5-Spd.,231 T/C Model 30 Dana Front
Axle Driveshaft w/2.000" tubing
1310 Series, 5.2 L Engine, Automatic, TC to FA 919649-1204 52098379
249 T/C Model 30 Dana Front Axle
Driveshaft Dbl. Crd and CV Joint

1995 1/2-96 GRAND CHEROKEE
1310 Series, 4.0 L Engine, I-6 Auto., TC to FA 919649-1412 52099260
249 T/C Model 30 Dana Front Axle
Driveshaft Dbl. Crd and CV Joint

1996 GRAND CHEROKEE
1310 Series, 4.0 L Engine, Man. 5-Spd., TC to FA 919376-1806 52098707 31.770
242 T/C Model 30 Dana Front Axle
Driveshaft w/1.750" tubing
1310 Series, 4.0 L Engine, Man. 5-Spd., TC to FA 919373-1410 52098789 28.020
231 T/C Model 30 Dana Front Axle
Driveshaft w/2.000" tubing
1310 Series, 2.5 L Engine, Man. 5-Spd., TC to FA 919373-1410 52098789 28.020
231 T/C Model 30 Dana Front Axle
Driveshaft w/2.000" tubing
1310 Series, 5.2 L Engine, Auto., TC to FA 919649-1104 52099246
249 T/C Model 30 Dana Front Axle
Driveshaft Dbl. Crd and CV Joint

1995 1/2-96 GRAND CHEROKEE
1310 Series, 4.0 L Engine, I-6 Auto., TC to FA 919649-1312 52098850
249 T/C Model 30 Dana Front Axle
Driveshaft Dbl. Crd and CV Joint

1995 1/2 GRAND CHEROKEE
1310 Series, 5.2 L Engine, Auto., TC to FA 919649-1520 52098501
249 T/C Model 30 Dana Front Axle
Driveshaft Dbl. Crd and CV Joint

1993-95 1/2 GRAND CHEROKEE
1310 Series, 5.2L Engine, V-8 Auto., TC to FA 918291-2111 53008427 32.870
231, 249 T/C, Model 30 Dana Front Axle

1993-95 1/2 GRAND CHEROKEE
1310 Series, 4.0L Eng., V-8 Auto., 231, TC to FA 918291-1900 52087805 30.530
242, 249 T/C, Model 30 Dana Front Axle

1992 1/2-95 GRAND CHEROKEE
1310 Series, 4.0 L Eng, Man. 5-Spd., TC to FA 915374-1614 52088090 28.020
231 T/C, Model 30 Dana Front Axle


1992 1/2-93 GRAND CHEROKEE AND GRAND WAGONEER
1310 Series, 4.0L Engine Aisen TC to FA 915374-1724 52098341 30.530
Warner, 231, 242, 249 T.C.,
Model 30 Dana Front Axle


****TC to FA Transfer Case to Front Axle****
****TC to RA Transfer Case to Rear Axle****

***Centerline To Centerline of Cross & Lengths Are Collapsed****
__________________




This information is here for you to play with. As for what is the easiest solution for picking up a used drive shaft, it is going to be a V8 WJ as it will be of correct length and you can grab the yokes you need. In the end you will definitely need the V8 WJ’s transfer case front output yoke regardless of what double cardan driveshaft you get. This is given.

Be advised that with any driveshaft listed, this document’s sole purpose is to provide information. For absolute certainty, consult your driveshaft specialist and take the measurements they want you to make.


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post #5 of 43 Old 02-22-2017, 06:34 PM Thread Starter
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Section 4 - Double Cardan Driveshaft Swap Write-Ups




4.1) Chris Hager's Rzeppa/Fixed Yoke -> Double Cardan Conversion



4.2) JGC99's Rzeppa/Rzeppa -> Double Cardan Conversion


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post #6 of 43 Old 02-22-2017, 06:35 PM Thread Starter
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Section 5 - Servicing Rzeppa Joints and UJoints


I have found a great video on YouTube that services the Rezeppa Joint and U-Joints specifically for our WJs, including the Double Cardan end.


5.1) YouTube video on replacing Rzeppa Joints and U-Joints



5.2) YouTube video on installing the Rezeppa and Double Cardan Driveshafts



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post #7 of 43 Old 02-22-2017, 06:44 PM Thread Starter
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Hope this helps.

Again a special thanks to those that helped!

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post #8 of 43 Old 02-23-2017, 04:58 AM
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Very helpful writeup! Could you edit it to spell Rzeppa correctly? https://en.wikipedia.org/wiki/Consta...#Rzeppa_joints
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post #9 of 43 Old 02-23-2017, 05:21 AM Thread Starter
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Quote:
Originally Posted by HarryH3 View Post
Very helpful writeup! Could you edit it to spell Rzeppa correctly? https://en.wikipedia.org/wiki/Consta...#Rzeppa_joints
Yeah I'll get that changed later today.

Thanks

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post #10 of 43 Old 02-23-2017, 06:48 AM
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I'm sure that Mr. Rzeppa would thank you.
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post #11 of 43 Old 02-23-2017, 03:24 PM
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Good resource, good job. And thanks for the mention, but in reality I contributed nothing more than encouragement. My only critique is that I would refrain from listing aftermarket website-based options with any specificity, in part because I would never recommend those listed. Rather, I would list sourcing options as junkyard (in person or virtual via www.car-parts.net); local driveline shop; or web-based shop.

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's

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post #12 of 43 Old 02-23-2017, 06:34 PM Thread Starter
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Quote:
Originally Posted by skain8 View Post
Good resource, good job. And thanks for the mention, but in reality I contributed nothing more than encouragement. My only critique is that I would refrain from listing aftermarket website-based options with any specificity, in part because I would never recommend those listed. Rather, I would list sourcing options as junkyard (in person or virtual via www.car-parts.net); local driveline shop; or web-based shop.
It was your posts that helped me choose the V8 WJ double cardan shafts over the other manufacturers (TW etc). So you did help.

I share the same sentiment as you do that people should first seek WJ double cardan driveshafts first. But this is an information page so I felt it was necessary to list them anyway. Maybe you can explain why you would never recommend the aftermarket companies like IRO, TW, and Carolina Driveline.

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post #13 of 43 Old 02-23-2017, 06:37 PM
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Quote:
Originally Posted by wjjeep19 View Post

Maybe you can explain why you would never recommend the aftermarket companies like IRO, TW, and Carolina Driveline.
Price.

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post #14 of 43 Old 02-23-2017, 06:51 PM
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Quote:
Originally Posted by 99WJ539918
Price.
Apart from cost, the principal reason is inferior components. My explanation is all over this forum, not rehashing it here and cluttering the thread any further. /end

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's

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post #15 of 43 Old 02-23-2017, 09:52 PM
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wjjeep19, Thank you for the post. I, like many others have had at one point in time or another a question about what DS to choose.

I'm glad I have the DC shaft. Also thought about going custom aluminum shafts so I can have a set for the street and a chromoly-steel set with back up for off roading. If I keep bouncing on rocks like I do I'm going to smash a DS eventually and be left on the trail.

Good write up.
Thank you
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