My setup: D44 rear, Detriot Trutrac, 4.56 gears, 35" duratracs.
Ok, so about two years ago I went wheeling in Moab/Colorado. Once I got back, I noticed what seemed like a bent rear axle flange. I swapped out the rear axle shafts for some chromoly shafts.
Went wheeling in Tennessee and rode some decent trails. I am always easy on the skinny pedal but will bump it in 1st gear if needed. After that trip, the typical brake squeak came back. Upon driving back home to Florida, I jacked up the rear end and ran the tires. Both had a wobble. I also developed an axle seal leak on the driver side.
I took the shafts out and sent them back to East Coast Gear Supply. They checked the runout and said they were within spec. I had already ordered another set though. When the new set came in, I tested them by running the Jeep on jackstands. I noticed there was still a wobble in the tires. So I removed the tires and noticed the wobble in the brake rotors. I removed the rotors and still observed the wobble in the axle flange on both sides. I said screw it and decided to drive it anyways. Not long after, the driver side seal started leaking again.
So to see if it just happened to be two faulty seals on the same side, I swapped the driver side axle shaft with the passenger side. I also added some diff RTV gasket maker on the bearing retainer plate and axle housing where the seal seats. I drove the Jeep about 30 miles and observed the driver side axle seal leaking again. The leak was coming from where the shaft meets the seal. Not where the seal touches the housing. I forgot to add, when swapping the shafts from side to side, it seemed the bearing race was out of round from the driver's side. When I tried to insert it into the tube, it would get stuck. However, if I turned it about a quarter turn, it would insert into the axle housing without issue.
So, after consulting with some other Jeepers, I guess there were some bad experiences with ECGS. We came to the conclusion that maybe the bearings were not being pressed on correctly causing the wobble and leak. So, I ordered some Ten Factory shafts from Marcus at RCO.
These shafts came in tonight. I installed these shafts and yet again, the wobble continues.
Has anyone had a bent axle housing causing a wobble in the shafts? I just can't think of anything else that could cause the wobble.
I'm so over fighting this rear axle that I am about the pull the trigger on a semi float dana 60. But I would like to diagnose this issue.
Also, other than the stock shafts, the splines on the shafts were straight with no visible damage. Now the original stock shaft's splines were slightly twisted.
I should add, the housing to the naked eye looks straight. I put an angle finder on the exposed parts of the tubes and both read the same. Apart from tearing the axle down and putting a rod through it, it appears to be ok. Just hoping somebody has been through this same issue and has found a solution.
Bump to the top because I am adding video links of the flanges.
ANd the passenger side: