Dana 18, Is This Bad Or Normal?

my d18 got pretty hot and I had the roller bearing intermediate shaft.
Was there metal in the fresh oil?
It was hot today.... I’d expect it to get warm quick. if ambient temp was 100 it should be much higher than that after driving.

 

No metal in the oil, everything looks good. I'm going to put it back together tomorrow and drive it so I can capture the noise.

 

I have a complete single stick d18 if u want to borrow it. Send one of the Kids up to pick it up.

 

Ok here's the awful sound it's making when coasting. Same sound with clutch in or out, 3rd or 4th gear. 18 second mark is where you can really hear it.

 

sounds like it's eating rocks.

Remember that loose sliding gear moves on those loose splines to engage the hi range onto the output shaft. Any play on the low range hear to shaft is added onto with play between the high range and low slider gear.

I would pack the extra case. I think now is the time for tera lows, tapered intermediate and a novak or AA output shaft. I feel it's all gotta come apart.

Maybe it's just new shaft and low slider to get by but I feel that would only be a bandage.
How are your driveshaft slip joints? Do they have any similar wear?

 

It sure sounds like bearings to me more than play in a shaft or play in the mesh. At any rate I think that was my final effort to be ready for Rubicon. The Jeep can spend some alone time in the driveway to think about what it's done, I need a break from it, been non-stop work for two weeks.

 

Maybe time for a Dana 20?

 

Skimmed through this thread, my apologies if this was mentioned. The video sounds like the driveshaft is out of phase or the u-joints are bad. And how’s the condition of the slip yoke?

 

Funny you mention that. I decided to change u-joints today since I had spares sitting here for the trail and the dshaft was out, it made no difference. Slip yoke is good. Not out of phase right? My driveshaft is horizontal and the offset is side to side but I can't see how that matters (maybe it does).



Still haven't ruled out a trans issue, I can't pinpoint the noise.

 

I would like that but the sump for my fuel tank is where the output of the D20 would be. A lot of work to move the sump. And I'm still not positive it's the Tcase making that noise.

 

That was my next question. How’s the pinion feel in the rear if you grab it and shake it? Any play? Acceptable backlash?

 

Just went out and checked. Backlash feels really good and I can't wiggle the pinion with all my might, seems good. In other news, I left the key in the ignition and my battery switch on after my drive to make that video... unfortunately nobody drove off in it

 

I wonder if you broke the nose cone that the release bearing rides on..... Or is the clutch adjusted too tight at the release bearing is riding on the clutch fingers???
Steve's SM420 makes a similar noise when the clutch is depressed.

 

It's possible. I have the right amount of pedal play in the clutch and clutch works perfectly. I've never broken a nose cone, would it still operate correctly with a broken nose cone? It does sound throw out bearing related but what's odd is the bad sound doesn't change at all with clutch in or out, coast in neutral, coast in gear with clutch in, coast in gear with clutch out is all the same noise.

Like Steve's, mine was making noise and that's when I found the broken tang on the clutch fork and figured that was the source of my noise but I guess not. Brand new U.S. made throw out bearing and LUK clutch fork install went smoothly.

 

We’re you able to verify the clearance on the release bearing?

 

That seems like A LOT of play on that sliding gear to me. There should be minimal to no rotational slop between the slider and it's shaft as I understand it. And as you were wiggling it, it looks like the intermediate gear was also moving around against it's thrust washer that is visible in the video. In a nutshell, I'd say that case has a lot of worn out parts in it. I'd probably look for a replacement transfer case or start looking for new guts for the one you have. Probably cheaper to replace the whole unit with a good one.

And, may I say, that is the flattest driveshaft I've ever seen in the back of a cj5.

 

No, I didn't try to. Just adjusted the pedal play. How do you verify it, seems like I would have to pull the trans back and do a bunch of measuring.

 

Yes I do have some play in the intermediate gear as well. For a D18 it's really quiet under load even with all the play in those gears.

I have a centered high pinion D44 rear axle which is why it has no vertical only horizontal offset.

 

If you have a centered rear diff.... I have a serviceable D20 up here.....