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Might end up pulling a Dan Stewart maneuver

Discussion in 'Early CJ5 and CJ6 Tech' started by w3srl, May 4, 2005.

  1. May 4, 2005
    w3srl

    w3srl All-around swell dude Staff Member

    Port Orange, FL
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    Nov 6, 2002
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    4,275
    Ok folks. Only seven days left until Tellico and the transfer case is worrying me big time. I have a spare (26-tooth unit that was original to my Jeep, but it was full of ATF :rofl: instead of 90wt.) that I can swap in, but I'm afraid that one is in worse shape than the one I have in the Jeep now.

    What are the symptoms of a Dana 18 that needs to be rebuilt? Does it whine at speed (more than usual) growl, pop out of gear, or what? What are the normal wear items?

    I took the day off tomorrow to finish up the odds and end on the Jeep, and I'm planning to pull the OD unit tomorrow to rule that out. I can live without the OD, but if the xfercase is bad, I'm prolly screwed.

    If it is worn, do they fail catastrophically when they go? What normally fails?
     
    w3srl, May 4, 2005
    #1
  2. May 4, 2005
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
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    Bring it with you, Joe and I will help you swap them if one fails.:D
     
    Mcruff, May 4, 2005
    #2
  3. May 4, 2005
    Boyink

    Boyink Super Moderator Staff Member

    Tulsa, OK
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    Sep 20, 2002
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    Animal was growling pretty bad at Tellico before...
     
    Boyink, May 4, 2005
    #3
  4. May 4, 2005
    sparky

    sparky Sandgroper Staff Member Founder

    Perth, WA
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    That was just Billy's stomach not Animal.
     
    sparky, May 4, 2005
    #4
  5. May 4, 2005
    MOP

    MOP Active Member

    Pullman, WA
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    Sep 25, 2003
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    Mine was growling pretty good in 4wd. When I tore it apart I decided it was only the fron output bearing that was bad. Prolly wouldn't have been a huge problem if I would have left it alone. The rest of my gears and intermediate shaft looked fine. My tranny OTOH was trashed, and responsible for most of the growling I was hearing. I would just drive it........ I doubt mine would have failed. Maybe you can throw the spare one on the trailer ;)
     
    MOP, May 4, 2005
    #5
  6. May 4, 2005
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
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    Sep 21, 2002
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    The most common wear item is the intermediate shaft. It can be replaced without pulling the t-case. Pull the bottom cover and grab the intermediate gear and try to move it. If it moves more than a minimal amount then the shaft or the bearings are worn. Normally the shaft is what goes.
     
    Glenn, May 4, 2005
    #6
  7. May 4, 2005
    w3srl

    w3srl All-around swell dude Staff Member

    Port Orange, FL
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    Nov 6, 2002
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    Hmmmm. I really don't want to get stuck on some trail at Tellico and have to have someone tow me back off the mountain. Guess I'll check the OD, top off the fluids and run the dog crap out of it until next week. If it survives, it goes on the trailer. If not, well, pass the crack pipe Dan! :D
     
    w3srl, May 4, 2005
    #7
  8. May 4, 2005
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
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    Joe didn't get towed off the mountain, just to the edge, then he coasted down the mountain.:D
     
    Mcruff, May 4, 2005
    #8
  9. May 4, 2005
    Glenn

    Glenn Kinda grumpy old man Staff Member

    Apopka, Fl
    Joined:
    Sep 21, 2002
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    The intermediate shaft is very easy to check. Drain the t-case oil, remove skid plate and t-case pan. Grab shaft and attempt to wiggle it.
     
    Glenn, May 4, 2005
    #9
  10. May 4, 2005
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
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    I would say run it. most likely you will be fine, you will be doing slow driving pretty much the whole time. Heat and speed will wear it down a whole lot more. Make sure it is full of oil and have a good time in Tellico. Maybe even install a radio so you cant hear it ;) I have my Dana 18 sitting on my shevlf, i can bring it with me incase something happens so you can have a spare. With as many people as we have we can install it in about 2 hours. :)
     
    DanStew, May 4, 2005
    #10
  11. May 4, 2005
    Project71-5

    Project71-5 BACON

    Gypsum, CO
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    Sep 24, 2002
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    Mine whines pretty good when coasting in 4 lo even after a complete rebuild.
     
    Project71-5, May 4, 2005
    #11
  12. May 4, 2005
    Southtowns27

    Southtowns27 Custom Title

    The Backhills of...
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    Like the bumper sticker says: "It's supposed to be like this" Just keep telling yourself that over and over ;) But in all seriousness, it'll likely be fine.
     
    Southtowns27, May 4, 2005
    #12
  13. May 4, 2005
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
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    A large chunk of the gear whine you hear from a dana 18 is the straight cut gears, beveled gears are always way way quieter than straight cut gears.
     
    Mcruff, May 4, 2005
    #13
  14. May 5, 2005
    67cj5

    67cj5 Member

    Oregon
    Joined:
    Oct 15, 2004
    Messages:
    347
    Try lucas oil stabilizer if you opt to drive it. It helps reduce whine . I mix 50/50 on older components and it seems help alot with gear whine. Its not a mechanic in a jar by any means, but it does work.
     
    67cj5, May 5, 2005
    #14
  15. May 5, 2005
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
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    Sep 22, 2002
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    I just mixed the 90wt gear lube 50/50 with Lucas 90wt gear lube, the Lucas already has the stabilizer in it. I did this same thing with my axles and my transmission.;)
     
    Mcruff, May 5, 2005
    #15
  16. May 5, 2005
    DanStew

    DanStew Preowned Merkin salesman Staff Member

    Lexington, South...
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    Lucas is good stuff :)
     
    DanStew, May 5, 2005
    #16
  17. May 5, 2005
    H8PAVMNT

    H8PAVMNT Rub his head for luck

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    If you have a bad int. shaft the likelyhood of a catastrophic failure is very slim. It'll just growl louder after riding the Tellico trails.

    Stuff it full of lube and lucas and run the piss outta it! :D
     
    H8PAVMNT, May 5, 2005
    #17
  18. May 5, 2005
    MOP

    MOP Active Member

    Pullman, WA
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    While we are on the subject and I haven't filled or re-installed my rebuilt tranny and tc yet. Should I run normal gear oil, drain it after a few easy miles, then fill both with some mix of lucas and gear oil?
     
    MOP, May 5, 2005
    #18
  19. May 5, 2005
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
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    I never drained and changed mine when I rebuilt it about 10 years ago. Mine got changed when I put the twin stick on last month.
     
    Mcruff, May 5, 2005
    #19
  20. May 5, 2005
    AKCJ

    AKCJ Active Member

    Fairbanks, Alaska
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    Aug 12, 2003
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    MOP - yes, I would run regular gear oil first, then drain and put in the good stuff.

    w3srl - the symptom of a worn out intermediate shaft I had was the loud banging sound of gear teeth breaking off the gears. I heard 3 or 4 of them go but when I took it apart there were about 10 or 12 of them busted. Both on the intermediate gear and the output gear. If you broke a tooth and it got jammed in a bad spot it would crack your case. I think you should pull the pan and do the wiggle test first.
     
    AKCJ, May 5, 2005
    #20
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