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Dana 18 - Premature Intermediate shaft wear

Discussion in 'Early CJ5 and CJ6 Tech' started by brunester, Jan 20, 2014.

  1. Jan 20, 2014
    brunester

    brunester Member

    Santa Cruz Ca.
    Joined:
    Aug 4, 2011
    Messages:
    97
    Hey Guys,
    I have a question...

    I have a 1 1/4" shaft Dana 18.
    I rebuilt it, and after about 1200 miles it was howling soo bad that I took it down and apart to have a look.

    The Intermediate shaft has really deep wallows.(its only 1200 miles old) (see the pics)

    I could very possibly have screwed something up in the rebuild, but I did follow the instructions very closely.(ricks guide)

    Does anyone have any ideas why this might have happened?

    I am also wondering if I should rebuild the entire case again, or just put a new intermediate shaft in and hope for the best?

    Thanks!!
    -Eric

    [​IMG]

    [​IMG]
     
    brunester, Jan 20, 2014
    #1
  2. Jan 20, 2014
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
    Joined:
    Nov 22, 2003
    Messages:
    8,126
    A few questions:

    -Where did you get the rebuild kit from, & did you replace the shaft at that time?

    -Did you use grease to hold the needle bearings in place while you inserted the shaft?


    H.
     
    Howard Eisenhauer, Jan 20, 2014
    #2
  3. Jan 20, 2014
    Jeepenstein

    Jeepenstein Me like Jeep.. 2024 Sponsor

    North Central FL
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    Jun 15, 2003
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    2,159
    I's be suspicious as to the quality of the hardening on the shaft..
     
    Jeepenstein, Jan 20, 2014
    #3
  4. Jan 20, 2014
    timgr

    timgr We stand on the shoulders of giants. 2022 Sponsor

    Medford Mass USA
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    Aug 10, 2003
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    23,596
    The generic intermediate shafts and bearings were known to have quality issues. Both Novak and Herm the Overdrive Guy offer high-quality intermediate shafts and bearings.

    I think that Walt is implying that when a shaft is put together with grease, the grease does not dissolve and the bearings slide on the shaft, damaging it.
     
    timgr, Jan 20, 2014
    #4
  5. Jan 20, 2014
    Fr8 dog

    Fr8 dog Member

    Cincinnati
    Joined:
    Aug 21, 2013
    Messages:
    50
    I agree with the grease idea. If you use grease, make sure to use a grease with a low melting point so that it melts out and is replaced by gear oil. I usually assemble mine with gear oil and a dummy shaft to hold things together until the the installation of the intermediate shaft pushes the dummy shaft out. The surface hardness could also be an issue.
     
    Fr8 dog, Jan 20, 2014
    #5
  6. Jan 20, 2014
    nickmil

    nickmil In mothballs.

    Happy Valley, OR
    Joined:
    Sep 23, 2002
    Messages:
    12,529
    What was said about the quality of shaft. Also, on assembly, do NOT use grease. Use petroleum jelly (Vaseline) or transmission assembly lube. They have a low enough melting point and will readily mix with the gear oil. Grease can also plug up the oiling holes not allowing the gear oil to flow properly.


    Sent from my iPhone
     
    nickmil, Jan 20, 2014
    #6
  7. Jan 20, 2014
    brunester

    brunester Member

    Santa Cruz Ca.
    Joined:
    Aug 4, 2011
    Messages:
    97
    Hey,
    Thanks for replying,

    The kit was purchased from Parts Mike. The shaft replacement was included in the kit.
    I replaced everything in the case.

    I did use petroleum jelly for the needles.

    So Im guessing that the shaft was just super soft?
     
    brunester, Jan 20, 2014
    #7
  8. Jan 20, 2014
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
    Joined:
    Nov 22, 2003
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    8,126
    That's undoubtedly it. I had one as well that wore per-maturely & there's been a lot of other people here that have been through this but your's is the worst/quickest I've heard of. Get the premium quality one as Tim mentioned above and you should be good. Note for the next time Herm also has available a kit with the hardened shaft & premium quality bearings- that's the one I used last time & I think well worth the extra money.

    H.
     
    Howard Eisenhauer, Jan 20, 2014
    #8
  9. Jan 20, 2014
    brunester

    brunester Member

    Santa Cruz Ca.
    Joined:
    Aug 4, 2011
    Messages:
    97
    Thanks for letting me know.

    Do you think I should rebuild the entire case again? or just get a new shaft?

    Thanks
    -Eric
     
    brunester, Jan 20, 2014
    #9
  10. Jan 20, 2014
    lynn

    lynn Time machine / Early CJ5 HR Rep Staff Member

    Huntingdon PA
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    Sep 20, 2002
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    3,437
    Also let Parts Mike know. He's always been a stand-up guy in my experience... maybe he doesn't know that a kit he's selling contains an inferior part.
    If it was me, I'd simply replace the shaft & bearings.
     
    lynn, Jan 20, 2014
    #10
  11. Jan 20, 2014
    Howard Eisenhauer

    Howard Eisenhauer Administrator Staff Member

    Tantallon, Nova...
    Joined:
    Nov 22, 2003
    Messages:
    8,126
    If it were me I'd do the whole thing again with the premium parts- the standard OMIX kits everybody sells use cheaper quality bearings & all the crud that came off your intermediate has been passing through them. If you already have it apart, & if you plan on keeping your jeep for a while, & if you can swing the $$$ for a new kit you'll sleep better at night :)

    H.
     
    Howard Eisenhauer, Jan 20, 2014
    #11
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