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So, the other issue with the 4:1 gear set is that the large gear on the intermediate gear is larger then the stock gear, so extra fun to remove and reinstall. When this case was empty, before starting the rebuild, I made a notch per the LoMax instructions for this gear to clear during...

More gear oily goodness. Taking more stuff apart. Only 6 nuts hold the Dana 300 adapter plate to the back of the AX15. And safely on the ground. First time pulling out a Dana 300 without the transmission attached to it. Not too bad. Shimmed up the high side of the case with a 2x4 to...

So, up next, try to eliminate/or at least greatly minimize the Dana 300 intermediate shaft leak. I have had good luck with Novak's intermediate shafts eliminating leaks, due to an o-ring seal on both ends. The OEM shaft, and most aftermarket rebuild kits, only have a seal in the front side...

Cleaned up, ready to take something else apart on it....

Back together, quick test drive, seems good to go. Might work on this next: Looks worse then it is, annoying Dana 300 intermediate shaft drip. That's it for now.

Of course all did not go perfectly in ole RedneckRay land. Snapped off cover to drive slug bolt. I installed these Yukon drive flanges last year, happy with them. IIRC last year, after installing them, I drove around with the rear wheel center caps off so I could check for leaks/looses...

Grade 8 flange bolts to replace the original Grade 5 bolts. I used 1" long bolts on the open ended holes, 3/4" long on the four blind holes. The thick differential cover easily accommodates the longer bolts, they barely protrude past the back of the housing. These new bolts did not have the...

Scooped out the old fluid from the master cylinder, compressed calipers, scooped some more old fluid out. Not a full flush, this fluid is from last year, so not too bad. New fluid installed. Back to the differential cover. Better to be lucky then good!!!!!! I was able to back out the...

Some grease here for the spindle bearings and big spindle seal. A bit more grease on the spindle bearings, anti seize around the back side of the spindle to keep it from rust seizing in place. I did this last time, worked like a charm when I disassembled the spindles this go around. Not...

Some emery cloth and polish on the seal portion of the shafts, a little spray lube on the rest of the shafts to keep the flash rust away. Since the differential was out, I took advantage and slid the axle shafts into position, figured it would be a bit easier on the rubber seals. The...

And the other side. So, this got me thinking. Happy with the tool, but why did I have to add pieces to make it work. Dug an old seal out the trash can, it fits perfectly on the tool, tool goes inside the seal like what I did on my second stack. Perfect! But why? So, my ring and pinion...

So, should have been a bit more careful. I gently started one of the seals, got a bit cocked. This was just getting it started. Repositioned everything, took a break, more careful, got it in true and square. Note, this is flush to the outer end of the tube, more on this in a bit. It...

This will be the longest Dana 30 inner axle oil seal install post in history, bare with me, might be useful. I ordered a "WeHope" brand Dana 30/44/60 inner axle oil seal install tool off Amazon, $20 to my door. No issue with the tool, seems well made, straight, true, good threads. Would...

Piddling, waiting on inner axle oil seal install tool, so some preliminary reassembly work. Stub shaft large spindle seals installed: Inner spindle seal then the plastic thrust washer.: Installed the inner wheel bearings into the hubs, the bearing with the larger ID. Hub seals...

And like all of my little projects, this one takes a detour, but not too far out of the way. Last time I messed with the front end I noticed the driver side axle shaft oil seal must have been seaping a bit. It hasn't magically gotten better, has not really got worse, but I told myself I would...

Post #1,952 on this thread helps me remember the big stuff. When I change the oil, I write date/mileage on the filter box lid and keep it in the console. Every 3k miles, oil change and grease all the zerks (steering/suspension/driveshafts/clutch linkage) Every 6k miles, same as above but add a...

Remembered to grease the ball joints. Only way to grease the upper ball joint is with the axle shaft removed. I keep these plugs in the zerk holes when the Jeep is being driven. The OD of the front axle shaft/u-joint assembly is too large to keep the upper zerk fitting in place. I only...

Those are idle mixture adjustment screws, NOT idle RPM screws. Yes, adjusting them will change RPM because you are adjusting the mixture, so it will increase RPM and can stall the engine. You usually leave those out IIRC 2.5 turns after gently bottoming them out. Then fine tune mixture from...

A little bit of work tonight. Packed the wheel bearings and spindle bearings, zip lock bags to keep dirt out. Installed the new rotors on to the wheel hubs. And the big accomplishment, well, at least for me 😆 New Spicer u-joints installed, no problems. I think I always dread...