05 Sport build (Mid Life Crisis)

I got some fluids and gasket maker.

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I got to work on the Jeep allitle today. Adjusted the front and got some caster back. I measured the ball joint angle with my iPhone rigid app. It read 5* caster and that put the DS roughly 1-2 * above the pinion.
I then took off the front diff cover and cleaned it up.

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The po had a dropped pitman arm and bracket that was wacking the cover. I choose to grind down that fin to make it look better. I still haven’t took the coils out to set up clearance and bumpstops.
 
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I’m still getting vibes under hard load and I’m pretty sure it’s the rear DS.
I bought a digital angle finder to get a little more accurate on the pinion angle. I have been using my I phone.

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Next up I’m going to order new u joints and centering ball for the dc driveshaft if I can figure out which one to order
 
I ordered (3) 5-1310x u joint to rebuild the rear drive shaft. These vibes are driving me crazy.🤬 I hope this fixes them. I’m thinking after changing the pinion angle the old joints were worn so they aren’t used to the change. I can tap the drive shaft and get a small clunk sound.

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I went to rebuild my rear dc drive shaft and ran into a problem. The rear is a greaseable one and I had a spair non greaseable centering ball yoke for the front.I ordered one from Amazon but it won’t be here till Tuesday.

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Read through your build.
Very impressed with the amount of work in a short time.
Only one thing.
I can't believe you were able to remove your pitman arm using PB Blaster. :D

Thanks I think I got a problem😁Pb blaster seams to work pretty good for me, but I’m not seeing a bunch of rusty bolts either.
 
Drove the Jeep to work this morning and finally I'm confident to say the vibes are gone and drives smooth now. Driving with the bad DC joint did cause my pinion seal to leak, so I need to address that.
Next will be a battery and figure out the darty steering,
 
I’ m still getting a knocking noise under load. So I checked the u joint I just put in and it’s loose still. I have a spare axle and new u joint I can swap in cause I’m not sure why it would have play still.

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Must have been a stretched stub shaft. Swapped in a spare stub and reused the u-joint and no play now. I’m still getting a popping sound under load.
I guess it’s this lunchbox locker.
I need to swap out the driver u-joint .
 
Well noise is still there🤬 they said either tc or trans. He said if I pull the tc out he would open it for free to diagnose.
Gears are good though. Gets up to speed effortlessly.
I also had them put a spring and pin kit in the spartan and now it’s banging and popping alittle.
I’ll put some lucus heavy gear oil in after break in.
 
This morning I swapped out the driver stub shaft with a spare I had cause it had play after a new u joint. Looks like both the stub shaft’s ears were stretched. No play in in them now.
About the noise in the front, I plan on driving it until it gets worse or I can confidently pin point it and fix it.