How NOT to swap an axle!!!

[jeepdreamer]

Ok,
So this is the first weekend ive had off in a while. I've been itching to get the rear axle swapped out in my 83 Cherk for a while. I've been slowly gathering all the bits and parts i thought i'd need to make it go smooth. Uh... NO!
Being in the Army i have to use our on post auto crafts shop. They have most things a halfway equipped shop would. They cahrge by the hour to use a bay, more if it has a lift... etc. So preplanning makes it go smooth and faster is cheaper. Gotta stretch the tiny check i get!
So i head down there this am, all excited to get wrenchin'! Takes me about 2 hours to get the rear 20 out (coffee and smoke breaks dont count, do they??;) ) Also gave advice to some fellow soldiers wrenching on thier projects. I had a little left to clean up on the replacement axle and the new perches. Finnally get the new axle under it and ready to start checking alignment and.... UH-OH!!! It doesn't FIT!!!:eek: I couldnt believe it!!!! The more i stare at it the more i swear! All this time... and now this!!! CRAP!
The offending axle in question, should anyone else think this would be a good idea, is a dana 44 from a mid 90's Isuzu Rodeo! WMS to WMS is within 1/4 inch. 6 lug bolt pattern. 30 spline axles. Disc brakes.And a much needed 4.10 gear ratio. The problem is the Rodeos springs are mounted much more inboard than my F/S Heep! The bolts holding the "outter" assembly to the tubes hit the leaf springs. And after looking a little closer, the brake calipers would mount about half way into the springs as well!!! **** that JP Magazine!!!! I swear they said it would fit!!! So much for reasearch. I guess i got tunnel vision worrying about the WMS to WMS and never thought it wouldnt fit some other way!!! **** ME!!
So now im starting all over... looking for an inexpensive axle that has around 4.10 gears and will fit in my Daily driver. Narrow trac, running 33's, 272 (STUPID IDEA JEEP!) gears, 258i6/T17? 4 speed.... not the best towing set up.!. And i NEED to be able to tow soon! Help!!! ANybody?? Ideas!!??!! Opinions on installing a used 4.10 R&P from a CJ model 20?

[Chevelleguy]

I was tossing around that same swap, glad to know it won't work. I guess the back plates are much narrower than the AMC?

The used AMC 20 ring & pinion will work if they are in good shape. I have installed used gears several times.

You MAY be able to use the Isuzu ring, pinion, and diff in your front axle but I am not sure about that.

[gsmikie]

have you priced a axle shaft for the isuzu ????? my last quote for a axle shaft was $400.00 PLUS

[jeepdreamer]

Yeah,
I blame me for not checking better. You'd think after lugging that stupid thing around and then tripping over it hundreds of times id have checked! I believe that due to the depth of the disc brake assemb. they made the tubes shorter to get the width they wanted for the Isuzu. Not exactly a cheap or easy fix there... sux! So much for the $89.00 pull-a-part super axle! I will use it on my Jeepster Commando project instead:cool:
As far as 400 bucks for a replacement axle?? Uh... NO!! I would be heading back to the junkyard for one! Granted, the 30 spline is prob. living on borrowed time if your running bigger than 35s (or if your wallet makes you drive like a medicated grandpaw, like mine!) but i think its great "bang for the buck" considering what you get. Maybe it would work on the older FSJs?? Are thier springs mounted inboard more??
I am really glad i didnt just cut the parking brake cables off when i started! I dont think i will bother running the dvrs side behind the tank for now... im hoping to swap tanks for something in the rear thats bigger and doesnt leak!!

[Gambler68]

that sucks. Trade it to a baby jeeper.

Do the discs from it swap to a FSJ rear 44?

[gsmikie]

the axle shafts are soft the bearing likes to eat the axle the replacement axle bearing is an axle saver i don't know how well it would hold up to the weight of the wagon i found this out after i put the northstar in my rodeo

[Sambo]

dang ted:( i feel for ya bro!
measure 120 times and swap once:D yes i am laughing with you my friend.
if weather dont get to hot monday and tues i will go out an pull the tranny so you can come get it when you need...btw i also have the rear axle(d44) under it as well(3.54 gears)...it would be a bit wider being under a jtruck!

[NVJEEPER]

I think ( according to search) 4.10 will cost not much at BJ's and fit your existing 20 carrier. Then if those "metric 44 " gears will work in the front you are set. The carrier info is from IFSJA so:thumbsup:

[Sambo]

funny i thought no one makes a different gear for that carrier! 272 is all by its lonesome!

[jeepdreamer]

Im not 100% on this but i think its 272 thru 355ish before the carrier change? Then 373ish up.?. I would love it if someone with lotsA knowledge on this can tell me a couple things:
Will the carrier from a CJ model 20 work in the FS 20?
I took apart the "lil" 20 from my cj to nab the locker (lokrite) for my FSJ. It had 4.10 gears in it... Will they work in my FSJ 20 using the cjs carrier??
What else do i need to get before it gets torn down? Bearings seals??? Help!?!
As bad as it was pulling the axle only to find the new one wouldnt fit... I cant tear the 20 appart and find out i need some obscure part that needs to be ordered. Its my daily driver!! Thanks all!!

[NVJEEPER]

funny i thought no one makes a different gear for that carrier! 272 is all by its lonesome!

oOPs i think you are right. now i gotta go find that thread

[Chevelleguy]

The CJ carrier should work in your FJS. I have never seen a listing for 'CJ only' of 'FSJ only' regarding aftermarket carriers.

[Sambo]

yep 2.72 all by it lonesome! so 3.07-4.88 will work unless they make 5.38's for that one now!

[JPSwapMohn]

The R&P from the Isuzu will work in your front axle. That is what I have in mine, with a LDS unit that was in the Isuzu. Isuzu used thick rings instead of changing the carrier, so the ring will actually work on your open front carrier as well. When you open the Isuzu diff. you will see that it has a sprocket-like gear under the ring. Worry not. If you leave it there it will just help throw grease inside the carrier. If you take it off, you will see that it sits in reliefs in the carrier and has no impact on the height of the ring. That isuzu housing should have a sensor mounting in it that reads that sprocket as part of the ABS (so I was told...not absolute on that).

I am pretty sure I still have a R&P set I pulled out of a rodeo/passport out in the back of my '78. They are pick-n-pull finds (no guarantee on wear, etc.), but you are welcome to them if interested.

Also depends on how comfortable you are setting up gears. I paid someone to do mine cause the idea of getting it wrong and having an axle lock up on me was one risk I preferred to mitigate.. I understand the process, but have never done one.

I don't know how long it would take to get them to you from 23831..