I think I can get a harbor freight caliper for cheaper too haha

 

I'm still at a loss though... The axle seal I remived, the numbers on it match up to the same exact numbers on the timken I posted. But,. Comparing side.by side the timken is too large, its like the metal housing/flange needs to be removed.

 

I suspect that the seal you removed was actually for the driver's side but the PO used a little redneck engineering and a BFH to stuff it in the disco hole. That would explain the matching numbers and the fact that the one you removed looks like something tried to eat it. A 2.122" diameter seal will NOT fit in that hole unless you beat it enough times to make it 2.00". There is an outer ridge, sort of a step in the bore of the axle tube at the disco, I wonder if the seal you removed was in that slightly larger bore? I'm not really sure and we'll probably never know but you need a 2.00" OD seal (the 2.062s are very rare).

While researching this I've come across a few people who have had issues with sealing due to the lack of a machined finish on the 1-piece axle where it mates with the seal so be prepared for possible leaks. The axle eats through the seal pretty quickly. I'm not sure if the shiny ring on your axle is caused from wear or if it was actually machined for the seal. If all else fails, you could always find the stuff you need to reinstall the 2-piece axle and vacuum disco, I know a lot of people hate on them but mine has been bulletproof.

 

Question if you have the inner seal the one in the disco holes not needed .....?

 

Sadly, there is no inner seal on the passenger side. Because the vacuum disconnect has to be lubricated, they moved the seal outboard of the disco. You have to remove both the primary and intermediate axles, along with the vacuum disconnect and you remove and re-install the seal through the disconnect cavity. It's a pain in the ***.

 

Wait, I'm not trying to install the seal at the disco, I'm trying to install it at the carrier... Should I be trying to install it at the disco? I've been following stu-off-road write up

 

Can you link the write up?

I'm assuming the wear line on your axle is from contact with the seal? That wear line is no where near the carrier. Where was the seal you removed?

 

http://www.stu-offroad.com/axle/d30seals/seal-1.htm

Old seal was removed from the carrier, well, in the diff right next to the carrier

 

Did some research this morning and came across this http://www.naxja.org/forum/showthrea...=978126&page=3
Looks like Napa #11800 should work.
Thoughts?

 

That plastic piece was the old bushing to support the inner axle. No longer needed for the 1 piece shaft.

Miles

 

So do you know what caused this wear on the axle shaft?

 

Learn some thing new every day...

Maybe heres the problem...

 

Seal in old axle connect area ?

 

Found this ....http://www.stu-offroad.com/axle/yjd3...jconvert-1.htm

 

You sure that broken piece is plastic and not cast aluminum? Looks like piece of the "coupler" that the shift fork slides to lock the axleshafts together.