Hi Everyone,
I just replaced the Intermediate shaft and CV axle on my 2005 4x4 3.7L Liberty AGAIN (4th time) and wanted to share some findings with the rest of you guys since I know this is an issue with these Jeeps. My buddy and I tackled this repair after researching the procedure on this site and using the part numbers I also found here. I bought a remanufactured CV and a new seal/o-ring from Jeep. I went through automotive parts unlimited for the intermediate shaft. I spent about $300.00 on the parts all said and done.
What I wanted to point out was that the stealership did this repair the previous times it was done. After finding that their repairs were only lasting 1-2 years, and were costing ALOT of money, I wanted to try to fix it myself. Im glad I did! The actual work to get the shaft/axle assembly out wasnt that bad and I had a suprising finding I wanted to share. When I pulled out the old intermediate shaft and CV axle, I found the the splines were completely lacking ANY type of axle grease to lubricate/protect the splines! I have NEVER heard of anyone mating a power coupling like this together without using some kind of axle grease. On top of that, there seems to be a groove machined into the intermediate shaft just after the splines where an o-ring fits perfectly..Im wondering if it is Jeep factory procedure to put the intermediate shaft and CV axle together in this manner??
Anyways, I greased the new splines with an appropriate amount of axle grease and my buddy (thanks Pat!) found an o-ring that fit perfectly into the groove on the intermediate shaft when I assembled the 2 parts. This seems to make much more sense than the way the parts were assembled that I just took off the Liberty. The splines are now lubricated, semi protected from moisture and dust by the axle grease and o-ring combo that pretty much seals the gap where the intermediate shaft and CV axle mate together. Is anyone else doing this when replacing these parts on their rigs? I dont claim to be all knowing or even a great mechanic, but this just seems to make a ton of sense to do while performing this repair. Any thoughts from you guys and gals? I know that repair has been covered ALOT over the last few years, but I didnt really see anyone specifically mention adding axle grease or an o-ring. Heres a couple pics of what Im talking about:

This is a pic of the o-ring I placed in the machined groove already on the intermediate shaft.

You can just see the machined groove right after the splines end.

Yep always use antiseize or grease on the splines
The o-ring never used since there should not be any dirt or moisture back in there
What the dealer did or did not do is hard to say for sure. I know most all that I have talked to ( the mechanics) grease then in some way. NEVER had them do it, just talking to them since they are friends of mine.
Where did you get the CV from? Just curious since I know how much NAPA are with exchange.
Hope this one lasts longer for you.
172,000 and only had to replace mine one time so I can see where you may be a little upset.

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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

Tommudd-
I bought the CV axle as a rebuild from a Jeep dealership. It was $138.00+ $75.00 core charge I got back with my old axle return. So $138.00 all said and done. It has the exact same factory warranty as the new one, but costs much less! And the new axle doesnt come with a core exchange, so your old axle will just sit around the garage..
Im seriously starting to wonder if the dealership "forgot" to add any grease to ensure that I would be back in to spend more money before too long. I know that sounds pessimistic, but they had to eat the entire cost of both the intermediiate shaft and CV axle+ labor as it failed under warranty that time. I would like to think that isnt the case, but I have seen too many shaddy things done at reputable shops to disregard the thought completely..
Im also wondering why there doesnt seem to be any issues with the driver side doing this..I havent had to replace anything on the front driver side at all besides brake pads/rotors..Any input on that?

Neil

BTW,
This o-ring isnt inside the differential housing where it is protected. This o-ring is on the end of the intermediate shaft outside the diff seal, so it is actually sealing the gap where the intermediate shaft and the CV axle meet up. In my mind, this o-ring is directly aiding in keeping moisture and dirt from entering these splines and causing damage. Maybe not completely, but definitly better than not having it in that spot.

Neil

Drivers side is a different setup, no intermediate shaft of course.
Didn't know that Jeep had rebuilts of course I haven't been in a Jeep dealership in over 10 years. Bought mine new online and they delivered it!
NAPAs CVs are 60-65 and work great
Yes I know where you installed the o-ring but it should help I suppose, can't hurt

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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

There is a C clip that goes on each end of the intermediate shaft to hold it together. Not an O-ring. the clip part # is 5066064AA it holds the axel to the shaft.

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05 White Limited

Bump for fixed pics.