Had a great day wheelin' at the Badlands yesterday w/LOST midwest & the KJ performed flawlessly. HOWEVER, about a 3rd of the way home i started noticing a strange vibration at certain speeds only to pull over & find that the passenger side driveaxle had separated from the driveaxle assembly about two inches. Also noted some fluid was leaking from the d.a. assembly (no suprise) but the axle shaft itself remains inside the axle assembly tube. Was able to take it slow to get to a friend's house in S. Chicago suburbs, then trailered it the rest the way home to my garage where it now sits. i am no mechanic so lemme' ask a few questions and rely on the knowledge and experience of others here:

1) What would cause the driveaxle to "walk" out from the assembly like that? Is there a bolt, clip, or thinga-ma-jiggy that should be holding that in place?

2) Can i simply tap the driveaxle back to the d.a. assembly, change/replace the differential fluid and be fixed? If so, what would keep it from "walking" back out on me?

- or -

3) Do i need to go ahead and disassemble everything (driveaxle, shaft, housing) and rebuild?

i will try to post picture of it tomorrow and update to this thread. Nevertheless, i'm sure there's a few out there with extensive experience who know what i'm referring to so go ahead and fire away. i'd love to be able to fix myself as i just dropped $440 last week at the stealership for brake work and miscellaneous others. As always thanx in advance!

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'04 Renny
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Conquests: Poughkeepsie Gulch, Governor's Basin, Black Bear/Imogene/Engineer/Cinnamon pass, Coal Creek OHV, Badlands OHV, S.M.O.R.R., K-Rocks, Parent's driveway

sounds as if the c clip came out allowing the axle to "walk out" There is a c clip that holds the axles in the housing, clip is located in the center of the diff by the way, you could pull the rear cover off and see if it laying in there, strange though... May be surprised to see what you do find,


tom

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MUDD'S MOTORSPORT'S We do IFS lift installs ,
03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited

Sounds like you may have broke the axle or stub shaft where it splines into the diff.. Dont know on the kj but it's quite common on ifs yotas.

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02' Sport- SOLD

07' Dodge Ram Quad Cab 1500 4x4
Yeah it's got a hemi!

MP Jeeper, hope you find the problem and get it fixed. I have no technical experience with this so I can't offer any advice other that of which you gave me. Keep yer chin up, get er' fixed, and get er' back out there with us! Hopefully this small mishap doesn't turn you away from wheeling. We'd like to see you out there again, to get a chance to run even more with us since I know you arrived late yesterday morning.

BTW...hopefully this won't drain your pocketbook as well as it does mine!

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02' Frankenlifted White Sport on 31" TrXus M/Ts

89' 2 Dr. Khaki XJ- Waggy 44's, 4.88s, 35's, 3-link on 5.5" coils.

unfortunatly it's all part of wheelin. gotta pay to play.

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02' Sport- SOLD

07' Dodge Ram Quad Cab 1500 4x4
Yeah it's got a hemi!

Partly true,there is a "C" clip on the ends of the CV's that hold the CV's in the diff.Though with a little force the CV will pop out of the diff.The little "C" type clips will/do wear out,I had to replace mine,and they can be gotten at a dealer,part# 05066064AA and are about $4-$5 apiece.They call it a snap ring by the way.

To replace you'll need to disassemble the Pass side suspension,pull the axle out.On the end of the long shaft that comes out with the CV shaft there is a clip looking thing at the very end in a groove in the splines(at least there should be,might have broken and fell off),remove and install a new one,push CV back into the diff,the new clip will make it tough to fully seat it so 2 poeple may be required to fully set the CV.Then reassemble the passenger side suspesion.If the clip is not on the end of the shaft you'll need to remove the front diff cover and fish out the peices so as not to ruin the front gears.


Here is a pic of the clip(2 are shown,bought a few spares),and yes it is pink,the drivers side looks the same but is not colored pink.

Thanx for the help guys. Put an order in for the part (getting extra as you did tjkj) and will fix (hopefully) later this week. Sounds fairly easy as long as the thing hasn't broken/slipped off inside the dif. Course now that i've said that it'll take me two days to do the job! Thanx again, you guys are great.

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'04 Renny
Mod's: See Avatar
Conquests: Poughkeepsie Gulch, Governor's Basin, Black Bear/Imogene/Engineer/Cinnamon pass, Coal Creek OHV, Badlands OHV, S.M.O.R.R., K-Rocks, Parent's driveway