SuperLift and front drive shaft

[lekmedm]

So, I'm starting this thread as kind of a place holder until I get more information.

The SuperLift provides drop brackets for the front diff to keep stock geometry for the front suspension components. Well, unfortunately this means the front drive shaft ends up with a more extreme angle. Here is a picture of mine at the transfer case:




Well, someone who had issue with this had a fabricator come up with a new shaft that uses a double cardan joint instead of the CV. Here's a pic:




I think I've read in a few places of some guys grenading their drive shafts while offroading. I'll post more info as I get some.

[TrialByFire]

FYI, I haven't had any problems with the front drive shaft. CVs, yes. Drive shaft (propeller), no.

[valpacer]

Ive had a custom shaft in mine for around a year now, dbl cardan top end to replace the CV, and the factory slip joint cv end at the Diff. I had to do this after smoking 2 driveshafts in 4 days :-(

Others have now had the same, and Jay has got Carolina d/s to make a design, which they will have the specs of to remake when needed.

[lekmedm]

Well, I found the boot on the CV at the TC to be torn, so I'll be giving the Carolina guys a call today.

[lekmedm]

UPDATE!!!!!!!!!

So the new drive shaft is in! I can confirm that a grinding noise and feel in the pedal that I've had since August is now gone.

So, first off, I will mention if I haven't already, that this will sooner be of concern to those with SuperLifts than those who have other lift that do not involve dropping the front diff. That's not to say everyone may not have front shaft issues at some point, but the SL owners may have this happen sooner rather than later.

So here's the new one:




















To be continued...

[lekmedm]

Now, getting the old one out and the new one in will require loosening the transmission crossmember:




And here is a look inside the joint at the TC of the old shaft. Nasty!






And the new shaft in place (bolts weren't all tightened down yet in this pic):





For $355 shipped, I'm thinking this worked out well. We'll see how this performs in the coming months, but I don't expect any problems.



Now if I could just get rid of the squeaking in the rear suspension...

[valpacer]

Looks good mate!

That's the best pics i have seen yet of the Carolina design.

Did they mention anything about loosing 2 of the transfer case flange bolts?

[Matt]

Looks good Mark!!

Is the shaft larger/smaller/equal to the stock shaft diameter? Wondering if it increased/decreased clearance to the annoying bolt in the crossmember.

[lekmedm]

I'll have to check on the stock shaft. The new one is 2" OD. It's my initial impression that they are the same. But the shaft diameter is an issue at the exhaust heat shield. It's the rezeppa joint that hovers over the captured nut in the crossmember. I had the back bushing in the diff replaced recently. I think that helped a lot to keep that from rubbing. I guess I should also check the diameter of that joint on both to compare.

[lekmedm]

Looks good mate!

That's the best pics i have seen yet of the Carolina design.

Did they mention anything about loosing 2 of the transfer case flange bolts?

Well, Dave, they didn't mention anything about it. Clearly, there is no place to drill the holes because of the flange design. I don't think it's an issue since the flange is a think, flat plate going right up against the TC flange for a solid connection. The rezeppas are probably a different issue, but I'm no engineer.