I've been reading and enjoying the write ups on this site as I work on making this 93 XJ a 4 wheeling monster. Normally, I can just glance through the forums and find a solution to a problem, but this one I can't.

Anyway, I have a D30 in the front right now, and it'll stay that way at least for the next year. It has no vacuum disconnect however. What I was planning on doing is either fixing the vacuum or installing a home brewed posi-lok to fix this problem I've been having. The problem is, when I engage 4 wheel drive the system engages but it makes a hell of a clunking near the front passenger wheel. It jerks a bit too. So, my thinking was that the disconnect wasn't moving the collar over enough to grab both axles. But then I find out that I don't have this type of system on the axle.

According to this article http://www.therangerstation.com/tech_library/Dana30.htm after 91, Jeep stopped producing the CAD model. What I don't get is the transfer case is a 231 which is part time from what I've learned. Which I would think would almost require a vacuum or posi lok system on the front axle.

I'm confused.

I don't think it's the transfer case thats screwed up, because the clunking and jerking sounds/movement are coming from the front, not under my seat.

The only other thing I can think of is the CV joints or maybe the teeth on the axle going into the differential are jacked up?

 

Probably the U joint at the wheel. A busted axle shaft might do something similar as well?

 

Any idea what size U joint I should have on this axle? Safe to believe it's the bigger ones? The 5-260x's or the 5-297x's?

 

I could be wrong but I don't think they started using the bigger ones til 97.

 

From 89 to 94 the larger 297 u-joints were used with ABS only, everything else has the 260s. From 95 and up all were equipped with the 297 u-joints.

 

Just looked again and I think it's 260. The joint has the collar on it like this pic which compares the 260 to the 297 which is on the bottom.



The thing that screws me up is, I would think that I'd still get at least a little clunking/jerking when not in 4wd but I could be wrong. I think I'll go ahead and replace the u joints tomorrow and when I pull the axles out it should be pretty apparent if the axle is broke. U joints are cheap, looks like about 14 bucks a piece for premium ones.

 

If you do have the smaller u-joints, then you can upgrade to the 297s by simply swapping in the later model axle shafts without any additional modifications.

 

Hmmm, that being the case, I may just go hit the junkyard and find 297's, replace the u joints on them, and then if I still have time pull the 260's out and slide the 297s with new joints in. May as well do it all at once.

 

Go agead and replace the 267 u-joints and keep those shafts as trail spares. The u-joints may be weaker but at least they will get you off of the trail and back home.

 

it is possible someone replaced the front axle with an older vac disco not knowing what exact axle they were looking for.
happened with my 93. when i bought it, paperwork was in the glovebox, mechanic didn't know about the different axles.

but it does sound like a u-joint issue on yours tho.

good luck.