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2006 Rubicon Unlimited

I have not been using a case spreader.

Here is the pattern I started with.
Driver: 0.129
Pass: 0.125
Pinion: factory 0.056
1000022464.jpg

1000022463.jpg

I initially added 0.010 to the pinion and got this:

1000022436.jpg

The another 0.010"

1000022437.jpg

Then I started from original again and started making the pinion shallower.

Pinion :0.052"
1000022620.jpg


And again to 0.047"

1000022621.jpg

And finally 0.042"

1000022622.jpg

Of all those, the I settled on the 0.052" depth as the "most acceptable" based on several sheets like this:

1000022493.jpg

Ideal? No. Acceptable according to the manufacturer? Yes. Backlash is in spec. I would have expected it to at least change the sound being made if it was something diff related.
 
Well, I swapped out the 80w90 for 85w140 and the noise changed a lot. Ordered new Motive Gear 5.13s, new pinion seal and new carrier bearings.

Hopefully this will be it.
 
Got the new rear gears installed last week and they are quiet as a mouse. I guess I cooked the last set driving it home.

Hoping the weather is nice this weekend and I can finish up the initial break-in on these gears and be ready for wheeling next month when the trails open!
 
TerryD said:
Ordered a high clearance transmission crossmember from UCF. Be nice to lose the dirt shovel.
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Which version? I’d love to get a lower profile skid but I don’t want to deal with lift motor/trans mounts.
 
nvrenuf said:
Which version? I’d love to get a lower profile skid but I don’t want to deal with lift motor/trans mounts.
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The one that fits all factory stuff without a body lift. Only gain about 1.5" of clearance but it's not nothing and smoother than stock so it won't hang up on stuff. Got the 1/4" thick so I can bash it.
 
not to hijack your thread but I ordered the fuel pump for my 2004 LJ a few days ago. it has been down for a couple of years, going to try to get it going. I need to sell it but don't want to.
 
fourwheelerjeff said:
not to hijack your thread but I ordered the fuel pump for my 2004 LJ a few days ago. it has been down for a couple of years, going to try to get it going. I need to sell it but don't want to.
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I'm sorry you're gonna sell it but that's EXACTLY why I DD mine. No sitting and getting pushed to the back burner.
 
TerryD said:
I'm sorry you're gonna sell it but that's EXACTLY why I DD mine. No sitting and getting pushed to the back burner.
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I'm going to hijack your thread to answer this and if you don't want it in your thread; PM me and I will make it disappear; no hard feelings.

I have 4 Jeeps; down from 6 a year ago. 2007 JKUR, 2004 LJ, 2000 TJ on SuperDuty axles, and a 1998 TJ. I have 2 Dodge diesels; 2002 dually and 2001 4x4. 2003 Silverado 1500. 1991 K5 (Babe the big blue ox, the only vehicle I have ever named in my life). 1988 K5 and 1976 K5. X Chassis tube buggy and 2 other tube buggies. 2003 Dodge 2500 with a Hemi. 1984 K20 (supposedly sold). 1982 K30 crew cab currently sitting without axles.
I constantly argue with myself about what to keep and what to sell. my daily drivers are either the JKUR or the 2001 Dodge; everything, even them; have issues. I want to keep the JKUR, TJ on tons, little TJ, both Dodges, Silverado, 1991 K5 and one tube buggy. I waffle between keeping the LJ and 1976 K5 as well. but I can't drive everything and they will end up just sitting. I really want to keep everything.
everything has been sitting for the last few years because of what has happened in my life I have mostly been sitting around feeling sorry for myself. Wife told me she wanted a divorce, moved in with parents, dad died, mom got foot amputated and is in assisted living, got robbed, retired, divorced and I wiped out my 401k paying her off, moved, paying a mortgage and rent. my life the past few years has been a sh!tshow I feel like.
I only make a third on retirement and since I wiped out my 401k; I just live on my retirement check every month.
 
fourwheelerjeff said:
I'm going to hijack your thread to answer this and if you don't want it in your thread; PM me and I will make it disappear; no hard feelings.

I have 4 Jeeps; down from 6 a year ago. 2007 JKUR, 2004 LJ, 2000 TJ on SuperDuty axles, and a 1998 TJ. I have 2 Dodge diesels; 2002 dually and 2001 4x4. 2003 Silverado 1500. 1991 K5 (Babe the big blue ox, the only vehicle I have ever named in my life). 1988 K5 and 1976 K5. X Chassis tube buggy and 2 other tube buggies. 2003 Dodge 2500 with a Hemi. 1984 K20 (supposedly sold). 1982 K30 crew cab currently sitting without axles.
I constantly argue with myself about what to keep and what to sell. my daily drivers are either the JKUR or the 2001 Dodge; everything, even them; have issues. I want to keep the JKUR, TJ on tons, little TJ, both Dodges, Silverado, 1991 K5 and one tube buggy. I waffle between keeping the LJ and 1976 K5 as well. but I can't drive everything and they will end up just sitting. I really want to keep everything.
everything has been sitting for the last few years because of what has happened in my life I have mostly been sitting around feeling sorry for myself. Wife told me she wanted a divorce, moved in with parents, dad died, mom got foot amputated and is in assisted living, got robbed, retired, divorced and I wiped out my 401k paying her off, moved, paying a mortgage and rent. my life the past few years has been a sh!tshow I feel like.
I only make a third on retirement and since I wiped out my 401k; I just live on my retirement check every month.
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You're fine man. I understand your feelings on this. I found myself spread way too thin several years ago. The GMC, Xterra, K5, 2 Camaros and a Monte Carlo SS. I wanted them all but like you, there wasn't enough of me or my paycheck to go around.

I downsized. Sold one Camaro, the Monte Carlo and the K5. Focused on the X for a DD/Wheeler and have been slowly working on this Camaro. It was hard letting go but worth it for my mental health. I don't have a dedicated trail rig because it will sit and not get worked on.

I have to DD my LJ so it forces me to plan my work and make repairs when needed instead of letting it sit and never get used like my K5 wound up doing in the end. So it's on the mild side, but I've taken it on 7 hour trips to the beach and wheel 4x more than my buddies with dedicated crawlers who have to trailer theirs everywhere.

IMO, 3 vehicles is about all one man can manage unless you can pay someone to work on them for you. So I understand your situation, as least as far as the cars go. I was by no means trying to throw off on you man. Everyone is different and DDing my LJ is the only way I can make sure I can keep it viable.
 
TerryD said:
I was by no means trying to throw off on you man. Everyone is different and DDing my LJ is the only way I can make sure I can keep it viable.
Click to expand...

I didn't think you were; thank you for letting me say my thoughts.
 
After I got the skid on, I took the Jeep wheeling and it developed a terrible rattle, bad bearing sound right between power and coast on the road. It was also still hanging in high and low 4wd randomly. I pulled the rear drive shaft and that went away. My best guess was something about the main shaft in the transfer case was shot.

With us working on getting Dad in a nursing home, dealing with the farm, and all that I thought "I'll just drop it at the transmission show and he'll have it fixed in a couple weeks while I'm dealing with Dad."

That was 5 months, two weeks and one day ago..... May 1st 2026. I finally got it back today and guess what, he said the transfercase looked brand new inside and he couldn't find anything to replace. He's a decent guy and since it took so long, he didn't charge me anything. It's been a rough year all around it seems.

Anyways, I spent this afternoon working on it. The first issue was the rear pinion was pitched up too much with the flat skid and it shook pretty good over 30mph. I extended the rear LCAs 3 turns and that pretty much cured that. The roar between power and coast was still there though.

I raised it up and shook and spun and banged and kicked about everything I could think of. The ONLY thing I could find was some rotational slack in my driveshaft splines. There's no up/down movement, just a little twist. Figuring it can't hurt to test, I pulled the rear shaft and drove in front wheel drive. No noise.

I had regreased the shaft when I replaced the u-joints but I used the synthetic marine grease I use for pretty much everything. I guess I didn't use enough and/or the synthetic got hot and ran to the ends. This time I packed it full of Lucas Red n' Tacky and took it for a drive. The noise is still just barely there, but greatly improved.

My best guess is that when it's unloaded in the transition from power to coast, the speed changes of the 2 joint shaft mixed with the tolerance stacking of the t-case, driveshaft splines, diff backlash, spider gear lash and axle shaft spline slop allows it rattle like a loose bearing would and transmits that into the transfercase.

This thing man. Always some weird ass stuff causing me a headache.

So Adam's or Tom Woods for a CV style shaft?
 
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