Check out this article.
Adapting the axle will be work, but it is not impossible. In order to keep it affordable, you just need to play smart.
Think of it like this: You are getting a 300 axle that needs $450 worth of gears and $300 worth of work to make it fit under your jeep. Then you are talking about an OX locker that will run you another $650 or so. Then you should think about the bolt pattern for the wheels. The article says that they are using a new one for the JK. That might mean that you will need to spend another 250 on new alloy shafts for the housing.
The junk yard deal looks better and better. You can usually pay the core charge and then get your cash back if you give them back your old axle. It is not like you will need it any more.
The grinder, and a sawzall will do the job. You don't need a plasma. Hell, most of them wouldn't cut metal that thick anyhow. Buy good cutoff wheels and blades for the saw. Try to cut off large pieces, then grind away the small bits and finish the tubes off for the new perches. The MAP gas torch is basically useless on a Jeep, but a good set of torches (small size tanks with regulators and cutting head) is affordable. You don't deal with too much rust, but they are a godsend to have on hand if you meet stubborn bolts. There is a reason they call it the "Heat Wrench" They really work.
Low pinion gears are different. A new set will run you the same price as a new high pinion housing from a junk yard. You should consider looking for a high mileage or wrecked Jeep (97-99) for parts. If the body or interior is hurt, you can get them for a song, pull your parts, and then recycle the carcass. Places around here will pick them up on a roll-back for free just for the scrap. That would give you a spare set of axles, transfer case, tranny, sensors, etc... if you are smart about it, you can get thousands of dollars of parts for a few hundred cash, then recycle the rest for a few hundred dollars.
as for setting up gears, the dial indicator is standard to determine basklash. the shims come with new gears. Basically, you put it together one way, check, take it apart, then add or remove shims. It is a lot of trial and error. Yes the one tool would work for all axles. They have a magnetic base and attach to all housings (maybe with a clamp for aluminum center sections?)
aren't Jeeps fun?
Adapting the axle will be work, but it is not impossible. In order to keep it affordable, you just need to play smart.
Think of it like this: You are getting a 300 axle that needs $450 worth of gears and $300 worth of work to make it fit under your jeep. Then you are talking about an OX locker that will run you another $650 or so. Then you should think about the bolt pattern for the wheels. The article says that they are using a new one for the JK. That might mean that you will need to spend another 250 on new alloy shafts for the housing.
The junk yard deal looks better and better. You can usually pay the core charge and then get your cash back if you give them back your old axle. It is not like you will need it any more.
The grinder, and a sawzall will do the job. You don't need a plasma. Hell, most of them wouldn't cut metal that thick anyhow. Buy good cutoff wheels and blades for the saw. Try to cut off large pieces, then grind away the small bits and finish the tubes off for the new perches. The MAP gas torch is basically useless on a Jeep, but a good set of torches (small size tanks with regulators and cutting head) is affordable. You don't deal with too much rust, but they are a godsend to have on hand if you meet stubborn bolts. There is a reason they call it the "Heat Wrench" They really work.
Low pinion gears are different. A new set will run you the same price as a new high pinion housing from a junk yard. You should consider looking for a high mileage or wrecked Jeep (97-99) for parts. If the body or interior is hurt, you can get them for a song, pull your parts, and then recycle the carcass. Places around here will pick them up on a roll-back for free just for the scrap. That would give you a spare set of axles, transfer case, tranny, sensors, etc... if you are smart about it, you can get thousands of dollars of parts for a few hundred cash, then recycle the rest for a few hundred dollars.
as for setting up gears, the dial indicator is standard to determine basklash. the shims come with new gears. Basically, you put it together one way, check, take it apart, then add or remove shims. It is a lot of trial and error. Yes the one tool would work for all axles. They have a magnetic base and attach to all housings (maybe with a clamp for aluminum center sections?)
aren't Jeeps fun?
www.4wheeloffroad.com
Check out this complete axle assembly for your Jeep Wrangler JK or TJ you can get for cheap inside 4Wheel & Off-Road Magazine.
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