Lane's official axle build-up thread

[Lka1988]

Ok, since I've been pestered by some to do this, I'll just start it now.

My plan: Rebuild the entire front axle. Chromoly birfields and axle shafts, Marlin Crawler HD seals, part-time hubs, and eventually a part-time kit into my truck (Katie). Possibly a new front diff (locker, maybe), too.

Now, let's go back a few months ago, about mid-November... I had this epic idea to play around on an ice patch in front of my house and do some donuts. Well, that ended in catastrophe when I punched it, felt a thud, and heard a gut-wrenching grinding noise....

I initially thought I had blown a birf (finally), but after tearing into the axle, I found the splines on the diff end of the axle shafts had actually been stripped clean off. With no 4WD for the winter, I ended up getting a set of snow chains to get me through the nasty snow storms. Used them only once.
Thread: https://forum.ih8mud.com/80-series-tech/340550-rth-blown-birf-still-drivable.html

Fast-forward two months, I was deciding between factory birfs and shafts or chromoly birfs and shafts + part-time kit. I found a set of FJ62 hubs in the junkyard for $22(!!!) and installed them purely for the awesome factor, so I ultimately decided to go with chromoly and part-time.
Thread: https://forum.ih8mud.com/80-series-tech/351604-convince-me-stay-full-time-4x4.html

 

[Lka1988]

Just a refresher... Here are the original axles and birfs when I pulled them out of Katie, around 265,000 miles. I'll be pulling the 3rd (eventually) to see if there is any damage (probably).

Pics 2-4 explain why I'm replacing the birfs. Totally trashed. Last resort trail spares, at best.

1. diff end of the driver side (long) axle.
2. Birf cage
3. birf
4. birf splines...almost gone.

 

[Lka1988]

Just last week, I purchased a set of new, never used chromoly axles and birfs from a fellow 'Mud member.
$500 + shipping (so like, $525).

Oooh, shiney....

 

[Lka1988]

Couple days ago, I had a new snap-ring groove machined in the birfs, much like Beno did....Actually, exactly like Beno did. Had a local guy do it for me for $25 apiece. AND he delivered them to me at work, since he was out doing errands already.

 

[Lka1988]

I already mentioned the hubs I purchased... Here are a few teaser shots

She just looks so natural with them...

 

[reconranger]

That ol' birf cage looks nasty. I suspect you had a click w/ turns???

Man, those blackened rims looks nice.

I always thought LC's should have locking front axles.

BTW, it would look more awesome w/ FF rears. Just saying.

Your rig looks nice, anyways.

 

[Lka1988]

That ol' birf cage looks nasty. I suspect you had a click w/ turns???

Just a little bit.

Man, those blackened rims looks nice.

Hells yeah! Taco rims, baby!

I always thought LC's should have locking front axles.

BTW, it would look more awesome w/ FF rears. Just saying.

In time. I'll probably replace my current 3rd with a normal open one, then stick an ARB or something in the old one and swap them out again. Then when I get 40x14.50x17's, I'll look into a FF rear.

Your rig looks nice, anyways.

Thanks

 

[OGBeno]

Lookin good Lane.

 

[mot]

Sounds like you've been busy!

 

[silverhorse]

Hubs on an 80 complete the package! NICE!

 

[wxm]

Good job, Lane.

 

[spdwaver]

Nice work, Lane!

You're going to miss that clicking sound, I guarantee it.

 

['74 UA FJ]

Couple days ago, I had a new snap-ring groove machined in the birfs, much like Beno did....Actually, exactly like Beno did. Had a local guy do it for me for $25 apiece. AND he delivered them to me at work, since he was out doing errands already.

What application are those longs for, since they are longer than the factory outer?

 

[Lka1988]

The Longs are modeled after the longer (no relation to the name) FZJ80 birfs. I have a 91 with the shorter birfs. The one on the left is one of my factory birfs with 265,000 miles

 

[Lka1988]

I totally forgot to post this...

Using Beno's measurements from his part-time thread, I whipped up a quick Paint sketch of where the new groove needs to be on the longer birfs. I'm a visual learner, so I needed to draw it out to see WTF he was talking about

It's not the prettiest, or even to scale, but it gives a visual idea and came in handy for my machinist

Hopefully it will come in handy for other 'Mud members as well.

 

[jlg32281]

nice work

 

[green40]

I see your parents wanted you to go thru life saying "no it's Lane not Wayne" too!
Nice job!
from the other Lane.

 

[Tapage]

that's what I need to do if I broke a stock birf ..

 

[nicholas]

I totally forgot to post this...

Using Beno's measurements from his part-time thread, I whipped up a quick Paint sketch of where the new groove needs to be on the longer birfs. I'm a visual learner, so I needed to draw it out to see WTF he was talking about

It's not the prettiest, or even to scale, but it gives a visual idea and came in handy for my machinist

Hopefully it will come in handy for other 'Mud members as well.

Nice work Lane. I'm fixin' to get a set of aisin's myself, however, I'll probably go ghetto-style and make a groove with a dremel tool or even better, a hack saw because I don't have the time to take the axle apart and I rebuilt it only 10K miles ago.

I figure a couple of hose clamps would serve as a good template and as far as I can tell, I should have enough clearance past the studs to cut the groove while the birfs are on the truck.

I've been driving a lot with the CDL engaged and the drive line removed and I like the way it drives. I'm thinking it will feel even better once the running gear inside the axle is no longer turning.

 

[Lka1988]

Nice work Lane. I'm fixin' to get a set of aisin's myself, however, I'll probably go ghetto-style and make a groove with a dremel tool or even better, a hack saw because I don't have the time to take the axle apart and I rebuilt it only 10K miles ago.

I figure a couple of hose clamps would serve as a good template and as far as I can tell, I should have enough clearance past the studs to cut the groove while the birfs are on the truck.

I've been driving a lot with the CDL engaged and the drive line removed and I like the way it drives. I'm thinking it will feel even better once the running gear inside the axle is no longer turning.

I'll tell ya, with nothing actually in the front end, it feels lighter and peppier than when there was still stuff in the front end, but not powered.

As of right now, Katie is a 2WD truck with a solid beam front axle, nothing more. Much like a semi truck, really, sans the second rear axle.