larryk wrote:So that shiny band on the diff end, where the bearings ride, isnt worn? I guess if there is nothing you can feel with your fingernail, just give it a quick cleanup with a scotchbrite pad, and you would be good to go. Somewhat concerned that you can insert and remove the shaft that easily though. Literally every intermediate shaft I have ever dealt with on these trucks is a tight fit in the diff....where you need at least a bolt in the end of the shaft and a pair of vice grips to pull it out.
Was your truck, perhaps, a flood salvage vehicle at some time? That's about the only way I can see that shaft getting so rusty.....as, while it isnt in a sealed cavity, the crossover tube in the pan is a fairly tight fit to the disco and tne diff.....so water incursion through normal use would be rare? Even going through a stream axle deep wouldnt necessarily get moisture in there sufficient to cause that much rust?
Yeah, I can't feel anything on that end, it just LOOKS like there should be wear there. I'm not terribly concerned about it going in and out easy, considering once you bolt the disco on the other side of it, it's not going to move. I'm also not too worried because I'm going to regear at some point once I have a rear axle, gears, locker(s), and some rear suspension components.
We thoroughly checked out all the history paperwork before we bought it and there's nothing about salvaged or damaged on there. I'm not sure how it got so rusty either, but as far as I can tell, moisture hasn't caused any major problems. If it's getting in through the diff side, I'll rebuild it later with the gear change. I'm running 33's and I've never put it through water more than an inch or two higher than the center of the wheel. Granted, I do have a little too much fun with the throttle when I plow through stuff like that, but that shouldn't really make a difference.
Last night I ordered bearings and seals to rebuild the disco, and an outer CV seal for the diff. Should be here saturday. I'll get that all put together with a new CV shaft and it should be good to go. I would put in a new intermediate shaft, but the cheapest one I can find is $200 bucks used on ebay. I DO have a 100k mile 4wd TB in the backyard that I bought recently for parts, I could pull it apart (all ive broken into so far is interior), if its worth all the work to get the shaft out. Should I break in there and get it or will this shaft be good enough?