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Cutting and welding differential for caster

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JT Nate

JT Nate

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I would assume any custom fab shop would be able to tackle it. There has to be someone around there.

Otherwise if willing to drive a little bit, Zues Offroad in MN has a stellar team and does axle fab work. 6ish hour drive each way from Chicago.
That’s good to know if I go that route. Thanks man
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I've done a couple of old skool Dana 44s and a 60.

It takes 6-8 hours if there isn't any brackets in the way, so I don't see it getting done for less than $1200 even in a cheap labor area by any one you could trust.

If the FAD thing doesnt work out, probably best to buy an aftermarket housing if you don't want to limit your shock length to 28.5 to run the OE driveline.
 

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I'm reading lots of bad info here and on the other thread
I have build many rigs from ground up and did alignment in an off road shop
I have 3" of lift on my gladiator caster at 6* and a lunch box locker (driveshaft spins) Zero vibrations


A. Optimum caster is 6* (weight bias and level of vehicle can change this)

B. Drive shaft angle (Front or rear) at T-case and pinion should be the same angle Unless you have a Dual Cardan shaft then the pinion should be 0*

C. A vibration from the driveshaft spinning is a result of being out of phase or poorly balanced


tom woods info (one of the best)
angles
https://4xshaft.com/blogs/general-t...le-cardan-drive-shafts-for-your-jeep-or-truck
vibrations
https://4xshaft.com/blogs/general-tech-info-articles/diagnosing-drive-shaft-vibrations
in phase
https://4xshaft.com/blogs/faq/driveshaft-in-phase
Bingo.
I think I've probably posted a lot of what you've said in other "I have a vibration" threads here - with some excellent YT videos showing it in a way you can't possible miss or confuse it (although some still walked away arguring)

Your post - spot on.
 
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I've done a couple of old skool Dana 44s and a 60.

It takes 6-8 hours if there isn't any brackets in the way, so I don't see it getting done for less than $1200 even in a cheap labor area by any one you could trust.

If the FAD thing doesnt work out, probably best to buy an aftermarket housing if you don't want to limit your shock length to 28.5 to run the OE driveline.
Makes sense. Hopefully the FAD route works out and I can share the cheap easy fix. Thanks for your wisdom man
 

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You are spot on. Do you think I would be able to wire it to an AUX? I’m a real idiot when it comes to understanding wiring.
It's as simple as it gets, 2 wire connection. Ground to ground and positive to the aux wire by the battery. It's low amp draw so aux 3 or 4 will work.
 

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I'm reading lots of bad info here and on the other thread
I have build many rigs from ground up and did alignment in an off road shop
I have 3" of lift on my gladiator caster at 6* and a lunch box locker (driveshaft spins) Zero vibrations


A. Optimum caster is 6* (weight bias and level of vehicle can change this)

B. Drive shaft angle (Front or rear) at T-case and pinion should be the same angle Unless you have a Dual Cardan shaft then the pinion should be 0*

C. A vibration from the driveshaft spinning is a result of being out of phase or poorly balanced


tom woods info (one of the best)
angles
https://4xshaft.com/blogs/general-t...le-cardan-drive-shafts-for-your-jeep-or-truck
vibrations
https://4xshaft.com/blogs/general-tech-info-articles/diagnosing-drive-shaft-vibrations
in phase
https://4xshaft.com/blogs/faq/driveshaft-in-phase
Your description of the double cardan proper geometry is wrong. The pinion should be pointed up at the transfer case output. This is where the cut and turn comes into play and the source of the OPs vibration. The more you lift the more the pinion needs rolled upwards. The problem there is rolling the pinion up reduces caster. With 3"+ of lift the caster will likely end up at 1 or 2⁰ and the thing would be undrivable. If there was an aftermarket high angle rzeppa shaft then you could set the pinion at 0⁰ and have shot 6⁰ of caster. Even with a lunchbox locker if you still have the FAD your front shaft shouldn't spin as there's no load so your side gears should be disengaged. If you still have the stock front shaft the rzeppa is allowing you to run enough caster even if the shaft is spinning.
Jeep Gladiator Cutting and welding differential for caster 41092464~2
 
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It's as simple as it gets, 2 wire connection. Ground to ground and positive to the aux wire by the battery. It's low amp draw so aux 3 or 4 will work.
Perfect thanks. I’ll update when it’s all done.
 
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Your description of the double cardan proper geometry is wrong. The pinion should be pointed up at the transfer case output. This is where the cut and turn comes into play and the source of the OPs vibration. The more you lift the more the pinion needs rolled upwards. The problem there is rolling the pinion up reduces caster. With 3"+ of lift the caster will likely end up at 1 or 2⁰ and the thing would be undrivable. If there was an aftermarket high angle rzeppa shaft then you could set the pinion at 0⁰ and have shot 6⁰ of caster. Even with a lunchbox locker if you still have the FAD your front shaft shouldn't spin as there's no load so your side gears should be disengaged. If you still have the stock front shaft the rzeppa is allowing you to run enough caster even if the shaft is spinning.
41092464~2.jpg
I was racking my brain on the 0° pinion angle. I’ve watched all those videos and even though I’m new to this (June of this year). I learn quickly and try not to put out crappy info. There are people on here that will be quick to judge and act as if you have done no research. They don’t ask questions first or they don’t read the info u put out earlier in the thread. I understand what is causing the vibration. I don’t know it all but I can tell you I’m not putting out bad information. Not sure if that comment earlier was pertaining to me. But I ran across a new issue an I’m just trying to solve it. You have been awesome and a ton of help. I appreciate it. I know the true fix is dropping a ton of money on a high pinion axle housing or upgrade to a complete high pinion front axle (Dynatrac pro rock 44 or Dana 60 with high pinion housing). If I were to go back I would still go 3.5 cause I love the break over angle. I truly think you have the best solution with the fad actuator install. Maybe this will help people in the future with 24 and ups. Thanks man for having my back.
 

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Your description of the double cardan proper geometry is wrong. The pinion should be pointed up at the transfer case output. This is where the cut and turn comes into play and the source of the OPs vibration. The more you lift the more the pinion needs rolled upwards. The problem there is rolling the pinion up reduces caster. With 3"+ of lift the caster will likely end up at 1 or 2⁰ and the thing would be undrivable. If there was an aftermarket high angle rzeppa shaft then you could set the pinion at 0⁰ and have shot 6⁰ of caster. Even with a lunchbox locker if you still have the FAD your front shaft shouldn't spin as there's no load so your side gears should be disengaged. If you still have the stock front shaft the rzeppa is allowing you to run enough caster even if the shaft is spinning.
41092464~2.jpg
I have a 3.5 lift. My shock length is 27.99" extended and so far no issues with the front drive shaft.

Caster is 3.89 on left and 3.76 on right. I have no clue on how it drives, but I am considering adding either adjustable control arms or geo correction brackets.

Caster of 1 or 2 degrees seems off.
Jeep Gladiator Cutting and welding differential for caster 20250716_000133
 

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I have a 3.5 lift. My shock length is 27.99" extended and so far no issues with the front drive shaft.

Caster is 3.89 on left and 3.76 on right. I have no clue on how it drives, but I am considering adding either adjustable control arms or geo correction brackets.

Caster of 1 or 2 degrees seems off.
20250716_000133.webp
Your caster is still crap and below the low spec Jeep puts out. Rolling your caster up to 6⁰ will point your pinion down another 2.25⁰ from where it's at. It will still be OK if you have the stock front shaft with rzeppa joint. The issue is the aftermarket double cardan shaft needs the pinion pointed at the tcase output, which would mean rolling your caster down to 1-2⁰. Nobody makes a long travel, high angle aftermarket rzeppa shaft so that's where the issue lies. With 3.5" of lift I'd rather see a 30" extended length shock, which would be too much for the stock shaft. It's a combination of factors that doesn't have an easy solution if you don't run a FAD. With the FAD you can set caster at 6⁰ and it won't matter if your double cardan shaft would vibrate a 60mph because most are never doing that in 4wd.
 

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Your caster is still crap and below the low spec Jeep puts out. Rolling your caster up to 6⁰ will point your pinion down another 2.25⁰ from where it's at. It will still be OK if you have the stock front shaft with rzeppa joint. The issue is the aftermarket double cardan shaft needs the pinion pointed at the tcase output, which would mean rolling your caster down to 1-2⁰. Nobody makes a long travel, high angle aftermarket rzeppa shaft so that's where the issue lies. With 3.5" of lift I'd rather see a 30" extended length shock, which would be too much for the stock shaft. It's a combination of factors that doesn't have an easy solution if you don't run a FAD. With the FAD you can set caster at 6⁰ and it won't matter if your double cardan shaft would vibrate a 60mph because most are never doing that in 4wd.
https://www.extremeterrain.com/tera...4314a585b18db78a890&gclsrc=3p.ds&gad_source=7


Get 2 of these

With the FAD installed.
And in 2H the driveshaft rotates freely.
I know because I ✔ checked. That means the front driveshaft is inert in 2H with a FAD
 

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I don't believe they allow any more angle than the stock one from guys testing them on the JL forum. I'll just stick with the FAD and good caster and not worry about the pinion angle. Yes you can run 60+ in 4HI, but I've never needed 4wd running that fast. The JTM lives mostly in 2wd because you can't drift turns very well at 70mph in the dirt in 4wd.
I still say solution for the OP is installation of a FAD and 6° caster. Despite his insistence that his JT has this and that ..blah blah. With the FAD the front driveshaft TaDo is eliminated. Cause when one is wheel in 4WD how fast does one really go I doubt I ever went much about 45mph in 4WD.
 

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Your caster is still crap and below the low spec Jeep puts out. Rolling your caster up to 6⁰ will point your pinion down another 2.25⁰ from where it's at. It will still be OK if you have the stock front shaft with rzeppa joint. The issue is the aftermarket double cardan shaft needs the pinion pointed at the tcase output, which would mean rolling your caster down to 1-2⁰. Nobody makes a long travel, high angle aftermarket rzeppa shaft so that's where the issue lies. With 3.5" of lift I'd rather see a 30" extended length shock, which would be too much for the stock shaft. It's a combination of factors that doesn't have an easy solution if you don't run a FAD. With the FAD you can set caster at 6⁰ and it won't matter if your double cardan shaft would vibrate a 60mph because most are never doing that in 4wd.
That's way below even low stock.
I don't understand why there aren't shafts made to deal with this. They all appear to be ignoring geometry and even function. They put the joints in the wrong location, IMO.
They all talk about keeping the joints at proper angles and pairing and so on, but then release shafts that do the opposite.
I suppose they are all assuming that shaft will never be turning at any speed at all, there will always be an axle disconnect and the shaft will never spin at speed on the highway.
But even that assumption is incorrect, even with a FAD.

(interestingly, I'd never heard it called a CAD - it was always front axle disconnect, even in 1981 when the Eagles came out with the SelectDrive.)
 

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https://www.extremeterrain.com/tera...4314a585b18db78a890&gclsrc=3p.ds&gad_source=7


Get 2 of these

With the FAD installed.
And in 2H the driveshaft rotates freely.
I know because I ✔ checked. That means the front driveshaft is inert in 2H with a FAD
No need to check - it's a given and why the disconnect exists. The carrier gears - side gears and spiders rotate. Left axle and left side gear rotate in a forward direction, spinning the carrier's spiders and causing the right side gear to spin in reverse direction. All power/torque is lost there. The carrier, thus the ring gear and pinion, are free to just sit there. It can move slowly in very cold weather as the friction of the cold fluid causes it to turn the whole carrier and the drive shaft (so if you get a very slow squeak, squeak, squeak sound on a cold winter day, could be the driveshaft is tuning really slow under there and rubbing on a shield or something - it's happened to a guy years ago.
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