Well if this isn't it, I'll eat my tailgate.....

I checked the track bar with the truck on the ground by clamping a piar of vice grips on it and tring to move it. It rocks just a bit but is pretty tight. Then I lifted each wheel and checked for play in the bearings.

Then I pulled the CAD actuator and sure enough the outer axle is flopping all around in there... the intermediate shaft bushing is non-existent.

When I did the right side ball joints, I of course pulled the axle out and put it back in without taking the CAD housing off. Whatever was left of the bushing could have fallen out, but this problem existed before I did the ball joints... but now of course is worse.

Anyway, local dealers are either closed or don't have it in stock, so I will order it. Question is what else should I replace? I think I am going to replace the CAD housing as it is corroded, new gasket, etc. What is the other bushing in this pic:

http://i416.photobucket.com/albums/p...ram/qk4646.jpg

??? anything else I should change while I am in there? How hard is it to change the outer axle seal? I'm not leaking fluid or anything, but it must have been taking a beating....


Thanks for the tip on the parts manual BTW, that is a great resource.

 

Larger bushing is for the inner, intermediate axle shaft. Some came from the factory with a needle bearing instead. (which is what I prefer......) They are also available online.

 

Only reason I like the composite one, is because it is wider than the metal needle bearing. If the shaft is worn the composite one will also ride on an unworn section of the shaft also.

 

I replaced the U joint on the front driveshaft today, after getting another one at Autozone for $14.99.. After watching a YouTube video on replacing U joints, I used my $69 "4x4 service kit" from Harbor Freight (same one that I did my ball joints with) and got it done in less than an hour. got my money's worth out of that tool kit for sure.

The intermediate shaft bushing and seal is on order for the front axle, as well as a new CAD actuator housing and gasket set.

 

Well I replaced the bushing and the vibration problem is now FIXED. Turns out I fixed 4 other things along the way, but that is only good.

I also replaced the axle seal that is in the CAD housing in the axle. It was one of those "pure luck" things where I 1) had an idea 2) it actually worked and 3) I actually had everything I needed to do it already in my shop.

I whacked the old seal out using a 24" long 3/8" drive extension and a 36mm socket:




I found this shallow "cap" in my washers drawer and a piece of 3/4" threaded rod. The cap edge sat right down in the back side of the seal between the seal lip and outer band.





I used an endcap from my wheel puller kit (the black thing) at the end of the axle, and locked a couple nuts to the outside end of the threaded rod so I could hold it and keep it from turning. I turned the nut against the washers and endcap at the axle end to pull the seal into the bore. It worked pretty good, except.....




This shows the nut and cap inside the axle CAD housing aligned and ready to pull the seal into place.




Well it kind of worked except the endcap steel was too thin, and in spite of having a thick washer over it, just collapsed onto the seal. So I went about trying to fab a better cap for the seal. I found a piece of 2" diameter thin walled tubing, and cut a short piece of it. I welded a washer on to the top of it.




This worked wonderfully and pulled the seal all the way in until it hit the seat of the bore.




Here is a pic of the axle reinstalled (although not pushed all the way in) and you can see the plastic bushing in the end of the outer axle (right) and centering the pin of the intermediate shaft in it. I was really afraid that I damaged some thing bad having driven this truck with that axle flopping all around in there, but nothing was even marred. Only damage was the seal that I replaced, it was trashed.



I took the truck out ran it up to 50+ mph and nary a sound or vibration, except for the howling rear differential....... Thanks for all the help with this.

 

Very nice. Great pics as well. (you are obviously aware of what pic ****** we are....)