You guys won't need a jig. If people want what I did to mine, I can supply a see through lexan overlay that bolts to your diff then bolt the tabs to the overlay and weld to the diff.

Likewise same for the passenger side. Once I have everything dialed in, I will split a piece of tube so that you can align the end cap that houses the seal/bearing.

I am doing this to an axle, why can't I make available the same pieces that I use, to you guys?

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

How did this become a gear debate? If you are installing a steel diff and welding it up, then your also gonna regear.

WhitebyKJ, if you supply the template, then its a easy job. Id buy a "kit" before i buy a new d30 from JBA.

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

I would buy a kit as well. When are we going to see what you got?

I was planning on posting pics today, but I can't seem to make it past the toilet today. Been vomiting since 11pm last night.

So I've been chatting from the iPhone in the bed.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

_________________
2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

What's the donor diff. from if I may ask? The template you are speaking of, will it have a means to hold the tube straight while they(the tubes) are welded back on to the center section?

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06 Renegade, 265-70-16 Duratracs on Moab's/OMF, RL sliders ,roof rack, On board air, JBA-UCA, adjust-a strut, Rear-OME 948 two uppers ,Sensatrac shocks, Boiler rad. skid, Mopar/4x guard skid,Terra-flex 4:1,HD cooling,more lights, gauges. ARB/Warn, Mudds Rear Bumper.

There is no welding of the tubes to the centre section.

The tube is 2.5 inches in diameter and 1/4 inch in thickness. I am presently designing an "end cap" that goes over the portion of the cut tube.

The diameter of the working surfaces on the intermediate shaft and drivers side cv are 1.316~.

The outside diameter of the bearing/seal assemblies is ~2.285.

So I must design a "cap" in it, holds the bearing/seal. This cap will get welded to the tube.

The axle is from a wj, factory gearing is 3.73.

I will not be regearing

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Gearing discussion goes along directly with any swap of a front diff if running larger tires
everyone should realize total cost just like any other project
Not sure why it can't be discussed as well

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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

Toms absolutely right.. Find a donor axle on ... Hmmm I think it's craiglist for you guys? ( kijiji up here) that has the appropriate gears in it alreadly and you don't have to pay for a regear!!

Lol you may just get one with a locker in it already

Tj, wj are what your looking for. Any low pinion dana 30

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Might want to re-word that,not all LP30's are the same.

Correct. You want a low pinion d30 with "short pinion" that way everything bolts in like stock.

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

Reworded: any low pinion 30 after 1996.5

From a tj or a wj (1999-2004)

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Forgot to mention an added bonus, you can sell the axle shafts, hubs, and abs sensors (if they are any good) and the xj guys use wj knuckles for bigger brakes and beefier steering. So you can sell the bits you don't use. At a minimum... For scrap.

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Reworded times 2:

Find a WJ axle, pop the cover off, count the ring and pinion teeth do the math, grab axle.

_________________
2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Do you happen to know when all the specifics of "the cap kit" will be available?

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________
06 Renegade, 265-70-16 Duratracs on Moab's/OMF, RL sliders ,roof rack, On board air, JBA-UCA, adjust-a strut, Rear-OME 948 two uppers ,Sensatrac shocks, Boiler rad. skid, Mopar/4x guard skid,Terra-flex 4:1,HD cooling,more lights, gauges. ARB/Warn, Mudds Rear Bumper.

Can't give you an exact day, sorry, but it should be ready by month end.

_________________
2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

I need an opinion from you guys.

Strictly speaking drivers side:

The wj axle seal goes on the inside of the casing and it's (the seals) inside diameter is 1.2".

Do you guys think we can get away with using the wj seal on the inside of the diff, meaning it will stretch .100" around the kj cv shaft, thus avoiding further machined parts... Or do you guys prefer an outside the diff kj style seal?

Using a wj style seal will drive down costs and save time. I believe it could work, being that the inside lip of the seal is lubricated and will just wear down to the correct size anyways.

Give me your input!!!

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2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --

Id use the correct seal. Once a seal starts wearing down, it looses that knife edge. But maybe someone else will chime in.

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.

Times two, a worn down seal does not seal as well as one that is the right one

_________________
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

Okie dokie. I'll have to design a cheap puller to yank the stub out with.

No probs bobs.

_________________
2004 KJ 3.7 Limited:
IRO WJ Upper Arm -- WJ Rear LCA's -- Rear Driveshaft Spacer -- JBA Upper A Arms -- 4 inch Lift -- 265/75/16 4" B/S -- WasherBottle Relocate -- Custom High Mount Intake -- Carpet Delete -- Homebrew Winch Bumper -- Warn VR8000 -- Homemade Plow -- Pinch Weld POUNDED -- POR 15 inner fenders --