D18 Problems

I'm having trouble with my D18. About 2 years ago, I had a problem with my D18 where the front output shaft was orbiting in 2WD. (It was like it was doing the hula but it wasn't turning.) It caused a severe vibrations that was loosening the front output housing. When I took it apart, I found the bushing in the end of the output shaft (which I had just replaced) looked as it does in the picture. I thought that I had driven the bushing in too far and covered the oil hole, so I replaced the bushing being more careful this time, replaced the front output shaft, put it all together and thought I was golden. Well now, after driving it very little in the past two years it's doing it again. Any ideas what is causing this?

 

could the output shaft be wore (undersized) causing the bushing to wear prematurely?

 

If you're talking about the rear output shaft, I suppose it could be, but the bushing seemed to fit tightly in it and it shouldn't wear as long as the bushing doesn't move. If you're talking about the front output shaft, I replaced it with a new one the last time this happened, so I'd say no, it couldn't have been worn.

 

front case distorted?? :?

 

Could be I suppose. Any idea how to tell?

 

I would say tolerance too tight (or lack of oil) overheating the bushing
as far as I know, no published specs for that bushing
mis-alignment possible I suppose, not likely though
what was the end play on the mainshaft, adjusted through the rear cap ?

 

I'm sure it's never been low on oil. I don't know what the endplay is. Guess I'll have to measure it. How would the endplay affect that bushing? I guess I coule see it if it were to loose and flopping around, but how would it hurt it by being too tight? I mean the shaft should stick out into the front housing the same either way right?

 

I may have thrown you a curve, just thinking out loud.
that endplay shouldn't affect that bushing; only the mainshaft its self and those bearings.
correct, the front shaft protrudes into the mainshaft
by the pic, it just looks like overheating/lack of lubrication to me
what was fitment like with the bushing installed in the mainshaft?
slipped in nice and easy?
if you say yes, I have no answers

 

Yes, it seemed to fit just fine.

 

Warloch,
Wow, Thanks! I may just do that. I probably won't be able to get to it for a while though. I haven't actually taken mine apart yet (The picture is from the last time this happened) but I suspect it looks similar.

Glenn,
No, that's just how I found it. It was folded back where the engagement splines are. I believe if anything I drove it in too far that time. I made sure it didn't block the oil feed hole this time, but it appear it's still screwed up.