Intermediate shaft opinions

My 18 tcase is getting pretty bad about "marking it's territory" so a re-seal is in order. It's also kinda noisy, so I was thinking about replacing the intermediate shaft & bearings. My question is, Advance adapters tapered bearing conversion or the Novak hardened shaft? Pros/cons? Cost is pretty close to the same, so I'm concerned with ease of installation, durability, and performance.

 

The AA conversion is quieter but requires machining of the Intermediate gear. This means replacement if damaged requires machining of another gear or going Back to the original design. The Novak shaft is appropriately heat treated like the factory shafts and use O-rings on both ends of the shaft.
Personally, I prefer the Novak shaft option as there is no machining involved. Many like the AA option for quiet, and lack of wear to the thrust washers (not used with the AA conversion). I have seen AA shafts fracture where they neck down but usually the case cracks at the same time.


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I installed Herm's kit a couple years ago and it seems to be as quiet now as it was after I first installed it.

 

Anyone else care to chime in?
I've got to admit, right now I'm leaning towards the Novak kit, just for ease of installation. I'd like to have the quieter operation of the AA kit, but between the whine of my Warm O/D and the howl of my Cooper STT tires, it's probably a moot point.

 

I just rebuilt with Kaiser Willeys kit, went ok and works great.

 

I ran the AA shaft for close to 20 years and maybe replaced the bearings once. I am back to the needles now thanks to the Teralow kit and most definately much more noise. Given the choice, I would go with the tapered rollers.

 

How much machining/modification is involved with the AA setup? Is it just modifying the gear, or are there case mods that need to be made as well?

 

Just the gear. They are very hard though and it must be very accurate.


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I rebuilt mine with Herm's kit, which is allegedly just as good as the Novak kit. While there is still so whine in the system, it's a Jeep. I kind of dig it! I am however intrigued by AA's tapered bearing setup, but I don't know if I like having to machine the gears.