The Ultimate front axle? - DodgeTalk : Dodge Car Forums, Dodge Truck Forums and Ram Forums
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post #1 of 73 Old 08-22-2011, 11:07 PM Thread Starter
RustyPW08
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Talking The Ultimate front axle?

Already on the PW. "T" steering linkage, '09 steering box set up for hydro assist. Have everything I need to finish that when the time comes. Modded PSC steering brace. Rock Crusher diff cover, Carli track bar. Now this below. Carli ball joints, RCV axles, and a DynaTrack FreeSpin Kit. Only thing missing is 5.13 gears.

I started to install all of my new parts today. I figured it would take me about 5 1/2 hours per side to tear it apart, and install everything for that side. WRONG! I got 8 1/2 ~ 9 hours in one side. I'll do the other side tomorrow. Nothing, I mean nothing come apart easy. I had to fight everything, but the ball joints coming out. They popped out with no problem.

1st pic. To get to this point was about 5 1/2 hrs.
2nd pic. Couldn't get the unit bearing out of the knuckle when it was still mounted to the axle. So I had the seperate the ball joints on the axle. Use a fiber cut off disc, and cut both studs on the ball joints to remove the knuckle.
3rd pic. The knuckle and unit bearing together.
Attached Images
File Type: jpg 018.JPG (248.6 KB, 39 views)
File Type: jpg 019.JPG (238.9 KB, 30 views)
File Type: jpg 020.JPG (282.9 KB, 31 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
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Last edited by RustyPW08; 08-23-2011 at 01:00 AM.
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post #2 of 73 Old 08-22-2011, 11:18 PM
TwinStick
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How did my once used tool work for you ?

08' PowerWagon w/6-speed manual G-56. 05' 30' toyhauler camper.(10,500lbs)
Hellwig LoadPro 35 bolt on 4 leaf helper springs.
No honey, I'm NOT done buying shit for the truck yet !!!
PurpleCrainium Diff Guards
K&N air filter --- WeatherGuard 20" black bed toolbox.
winch TPC bypass
Dual battery set up w/2 Sears DieHard Platinums-Gp 65 under hood-Gp 31 Marine deep cycle in bed toolbox w/plug-n-play set up. Custom 2000/4000w inverter set up w/quick connect. Triple bike mounts above the bed- custom made by me.
Crapload of recovery gear-always subject to adding more.
Fab Four rear bumper. Soon to be- a BuckStop Baja front bumper.--Temporarily on hold, see reason below.
Installed: Borgeson #000951 steering shaft. PSC steering brace(notched for PW by Rusty-thanks bud). Carli HD CroMo adjustable track bar. Carli CroMo control arms. Carli HD upper & lower balljoints x 2 sets (replaced under warrenty) & triple sealed u-joints in front axle shafts & rear driveshaft. Moog HD tierod ends x 4. Running total is now $4800. Yup, now i'm broke !!!


What, you ask, is the difference between a Dodge Ram and a PowerWagon ?? PW frame part # 55398868AC---Reg 2500 #55398813AC
About 2" taller, 12,000lb winch w/mounting brace between framerails,electronic disconnecting swaybar(for awsome articulation),electronic locking axles front & rear(for true 4-wheel drive),tow pkg, fully skidplated,forged one piece Alcoa rims w/internal beadlock lips,larger diameter(one ton) axleshaft in rear,160 amp alt,HD battery,4.56 gears,low range electronic recalibration of gas pedal sensitivity,more but thinner leafs in rear spring pack(for better articulation), 33" BFG All-Terrain tires. 78.016:1 crawl ratio. All for $6100.00 more! Oh yeah, almost forgot-Bilstein shocks. Gear ratios: 1st 6.29:1 2nd 3.48:1 3rd 2.10:1 4th 1.38:1 5th 1.0:1 6th .79:1.. Rev 5.74:1.
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post #3 of 73 Old 08-22-2011, 11:18 PM Thread Starter
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Talking

Everything is off the axle, so now I'm starting to install the new parts.

1st pic. The lower ball joint went right in with no trouble. The top Carli ball joint is taller then the stock one. Problem.
2nd pic. The problem is that the installing cup has a step machined inside of it. It fits the stock ball joint no problem. On the Carli ball joint. It don't sit down far enough to touch the rim.
3rd pic. Fixed problem. I took a grinding wheel on a die grinder, and ground the step back some until the cup fit down over the Carli ball joint.
4th pic. See, I wear shoes when working on the PW.
Attached Images
File Type: jpg 021.JPG (247.3 KB, 21 views)
File Type: jpg 022.JPG (259.1 KB, 23 views)
File Type: jpg 023.JPG (250.2 KB, 21 views)
File Type: jpg 024.JPG (268.0 KB, 21 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
,
Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Survivor of The Cold War,
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Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


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post #4 of 73 Old 08-22-2011, 11:23 PM Thread Starter
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Talking

1st pic. Ball joints are in.
2nd pic. Beating the snot out of the unit bearing, to remove it from the knuckle.
3rd pic. The axles.
Attached Images
File Type: jpg 025.JPG (251.9 KB, 19 views)
File Type: jpg 026.JPG (289.7 KB, 20 views)
File Type: jpg 027.JPG (285.0 KB, 19 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
,
Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Survivor of The Cold War,
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Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


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RUSS
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post #5 of 73 Old 08-22-2011, 11:36 PM
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When it comes to the ball joints I completely understand! It took alot for me and a neighbor to change both in one night.
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post #6 of 73 Old 08-22-2011, 11:37 PM Thread Starter
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Talking

1st, 2nd and 3rd pic's. Had the axle installed and the spindle bolted up to the knuckle. Put the rear bearing in the hub, and installed the seal for there, when I found this. The boot seal. Had to remove the spindle and axle to install it on the axle.
4th pic. The boot seal installed.
5th pic. The spindle installed.
6th pic. The wheel studs that come with the kit are too long. Can't reuse the old ones, as they won't stay tight in the hole. Nobody in town had enough studs to help me out. So I'm going to order studs that are shorter. And install them later. For the time being. I cut the end of the new stud off. right where the pencil is pointing at, is where I cut. I double checked to see if my lug nuts would bottom out. I'm good.
Attached Images
File Type: jpg 028.JPG (255.8 KB, 17 views)
File Type: jpg 029.JPG (280.6 KB, 16 views)
File Type: jpg 030.JPG (272.0 KB, 15 views)
File Type: jpg 031.JPG (239.7 KB, 14 views)
File Type: jpg 032.JPG (269.1 KB, 18 views)
File Type: jpg 033.JPG (234.8 KB, 19 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
,
Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Survivor of The Cold War,
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


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RUSS
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post #7 of 73 Old 08-22-2011, 11:45 PM
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looking good man!


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Green 03 Ram 2500 SC 5.7L HEMI


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post #8 of 73 Old 08-22-2011, 11:46 PM Thread Starter
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Talking

Something I forgot. When you install the axle. You have to grind alittle in the bore of the knuckle for clearance so that the CV joint can pass through. I used my die grinder with a grinding stone. Just need a little bit. You also have to put the red cup seal behind the knuckle, then slide the axle shaft through the knuckle bore, into the red cup seal, then into the axle tube. The red cup seal is bigger then the knuckle bore. They tell you all of this in the instructions. Once you have the spindle mounted. You now can slide the red cup seal over the CV joint ball. I had to pry it on.

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
,
Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Survivor of The Cold War,
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


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RUSS
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post #9 of 73 Old 08-22-2011, 11:51 PM Thread Starter
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The next 3 pics. Everything on the right side is buttoned up. The hub doesn't stick that far out. It's about flush with the rim lip. My butt is draggin'. Do the left side tomorrow. Should go quicker. Now that I know what I'm doing.
Attached Images
File Type: jpg 034.JPG (262.0 KB, 20 views)
File Type: jpg 035.JPG (267.3 KB, 22 views)
File Type: jpg 036.JPG (284.9 KB, 28 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
,
Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Survivor of The Cold War,
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.


RUSS
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post #10 of 73 Old 08-23-2011, 12:04 AM
TwinStick
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Awesome !!!

08' PowerWagon w/6-speed manual G-56. 05' 30' toyhauler camper.(10,500lbs)
Hellwig LoadPro 35 bolt on 4 leaf helper springs.
No honey, I'm NOT done buying shit for the truck yet !!!
PurpleCrainium Diff Guards
K&N air filter --- WeatherGuard 20" black bed toolbox.
winch TPC bypass
Dual battery set up w/2 Sears DieHard Platinums-Gp 65 under hood-Gp 31 Marine deep cycle in bed toolbox w/plug-n-play set up. Custom 2000/4000w inverter set up w/quick connect. Triple bike mounts above the bed- custom made by me.
Crapload of recovery gear-always subject to adding more.
Fab Four rear bumper. Soon to be- a BuckStop Baja front bumper.--Temporarily on hold, see reason below.
Installed: Borgeson #000951 steering shaft. PSC steering brace(notched for PW by Rusty-thanks bud). Carli HD CroMo adjustable track bar. Carli CroMo control arms. Carli HD upper & lower balljoints x 2 sets (replaced under warrenty) & triple sealed u-joints in front axle shafts & rear driveshaft. Moog HD tierod ends x 4. Running total is now $4800. Yup, now i'm broke !!!


What, you ask, is the difference between a Dodge Ram and a PowerWagon ?? PW frame part # 55398868AC---Reg 2500 #55398813AC
About 2" taller, 12,000lb winch w/mounting brace between framerails,electronic disconnecting swaybar(for awsome articulation),electronic locking axles front & rear(for true 4-wheel drive),tow pkg, fully skidplated,forged one piece Alcoa rims w/internal beadlock lips,larger diameter(one ton) axleshaft in rear,160 amp alt,HD battery,4.56 gears,low range electronic recalibration of gas pedal sensitivity,more but thinner leafs in rear spring pack(for better articulation), 33" BFG All-Terrain tires. 78.016:1 crawl ratio. All for $6100.00 more! Oh yeah, almost forgot-Bilstein shocks. Gear ratios: 1st 6.29:1 2nd 3.48:1 3rd 2.10:1 4th 1.38:1 5th 1.0:1 6th .79:1.. Rev 5.74:1.
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post #11 of 73 Old 08-23-2011, 12:09 AM Thread Starter
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Talking

Quote:
Originally Posted by TwinStick View Post
How did my once used tool work for you ?
Quote:
Originally Posted by RustyPW08 View Post
Everything is off the axle, so now I'm starting to install the new parts.

1st pic. The lower ball joint went right in with no trouble. The top Carli ball joint is taller then the stock one. Problem.
2nd pic. The problem is that the installing cup has a step machined inside of it. It fits the stock ball joint no problem. On the Carli ball joint. It don't sit down far enough to touch the rim.
3rd pic. Fixed problem. I took a grinding wheel on a die grinder, and ground the step back some until the cup fit down over the Carli ball joint.
4th pic. See, I wear shoes when working on the PW.
Answer your question. LOL

Thanks for selling it to me. That is the only way you're going to remove and install the ball joints.

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
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Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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post #12 of 73 Old 08-23-2011, 01:55 AM
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The way that I have seen the hub bearing assembly separated is to leave the 4 bolts threaded in a little and use the power steering along with a spacer in the gap to allow it to press a little on each one going around and doing each bolt only a little until it is free. Takes two people (one for the steering input and the other to keep and locate the spacer used to press it out). Works great even on rusted ones so long as you soak them w/PB Blaster first!

Cummins forum has a good write up on the entire job you just did! Won't let me post the link on here though.

I can post this though...

http://www.google.com/search?rlz=1C1...ge+hub+removal

Yes I did some mods to my PW... what about it?
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post #13 of 73 Old 08-23-2011, 06:27 AM
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Quote:
Originally Posted by azracer View Post
The way that I have seen the hub bearing assembly separated is to leave the 4 bolts threaded in a little and use the power steering along with a spacer in the gap to allow it to press a little on each one going around and doing each bolt only a little until it is free. Takes two people (one for the steering input and the other to keep and locate the spacer used to press it out). Works great even on rusted ones so long as you soak them w/PB Blaster first!

Cummins forum has a good write up on the entire job you just did! Won't let me post the link on here though.

I can post this though...

http://www.google.com/search?rlz=1C1...ge+hub+removal
When I removed my hub bearings, I removed the four bolts and then I used my air chisel carefully all around each side to slowly loosen it up and it popped right out of the knuckle while still on the axle. There was only one little spot that I had to grind down before I installed the new hub on the knuckle. Worked like a charm. Hopefully this helps anyone if you ever try this repair.
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post #14 of 73 Old 08-23-2011, 07:46 AM Thread Starter
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Angry

I tried all the tricks on that SOB. The air chisel, backing the bolts out and using the power steering. It took me about an hour to beat that bearing out. It was STUCK!

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
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Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Last edited by RustyPW08; 08-23-2011 at 11:31 PM.
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post #15 of 73 Old 08-23-2011, 10:13 AM
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Do you still have the stock rims anywhere? I wonder how far out the hub sticks with the stock rims?

Looking good!!!

'06 Power Wagon
-Thuren Fab Control Arms
-Thuren Fab Lift Springs
-Thuren Fab Track Bar
-35" Duratracs

'10 4Runner SR5
-Nitto TerraGrapplers
-Bilstein Leveling Lift
-Wife ride
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post #16 of 73 Old 08-23-2011, 06:20 PM
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very nice
Why the problem with the upper ball joint? because its a power wagon? meaning will I have the same issue(2500).I have the Carli ones too,waiting for my original ones to go bad

I would like to know how much you like that free spin kit,once your done and test it out.......


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Silver Truck Club Member#127

2004 2500 Hemi - Off-Road Pkg.w/4.56's
6" Lift PP Long Arms/Coils/Bilstein 5160's/ Dynatrac free spin hubs/Dynaloc hubs/spicer axle ujoints,
Carli Ball Joints/Carli deaver 4" leaf springs/Thuren Shackles/Carli Long Travel Air Bags
37x12.5x17 Cooper STT's/XD Enduros
n-fab step bars with Line-X
MagnaFlow (#14329)/Superchips
20% tinted windows Don Thuren steering stabilizer True Flow CAI
Tonneau cover/Husky liners/4-channel Amp/
Rockford sub/ Panasonic HU/kenwood speakers Hella 500's behind grill/Wheel Liners/Bushwacker Pocket style flares/Aeroforce Interceptor/BD Steering Box Stabilizer/steering upgrade,Carli Trackbar/ retrofit projectors,infiniti FX35 projectors,shaved,black matte paint,6k,from Unique Coatings.


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post #17 of 73 Old 08-23-2011, 11:35 PM Thread Starter
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Quote:
Originally Posted by silverhemidan View Post
very nice
Why the problem with the upper ball joint? because its a power wagon? meaning will I have the same issue(2500).I have the Carli ones too,waiting for my original ones to go bad

I would like to know how much you like that free spin kit,once your done and test it out.......
The issue I had was with the installing cup that fits over the top of the ball joint. There is a machined step inside the cup that is not deep enough to fit over the Carli ball joint. So I took my trusty little die grinder and went at it. Just had to move the step back less then a 1/4" so the cup would fit over the ball joint.

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
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Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Survivor of The Cold War,
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post #18 of 73 Old 08-24-2011, 12:00 AM Thread Starter
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More pic's of todays left side install. It only took me 5 hrs for this side. After I got done. I cut the grass and washed the outside of the camper.

1st. pic. My knuckle remover tool hooked up to the air hose.
2nd, and 3rd pic's. Just you show you the differences in the axles.
Attached Images
File Type: jpg 039.JPG (272.5 KB, 16 views)
File Type: jpg 040.JPG (271.4 KB, 15 views)
File Type: jpg 041.JPG (251.0 KB, 13 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Survivor of The Cold War,
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Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
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"Moab '10, '12, '14",
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post #19 of 73 Old 08-24-2011, 12:04 AM Thread Starter
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1st pic. Removing the lower ball joint.
2nd pic. Removing the upper ball joint.
3rd pic. Could not have done it without these tools. THANKS TwinStick.
Attached Images
File Type: jpg 043.JPG (255.8 KB, 12 views)
File Type: jpg 044.JPG (284.6 KB, 10 views)
File Type: jpg 045.JPG (255.1 KB, 11 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Survivor of The Cold War,
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Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
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"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


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post #20 of 73 Old 08-24-2011, 12:22 AM Thread Starter
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1st pic. I had to clean up the bore so that the CV joint could pass through it. Used a stone first to take off the heavy rust, then used a flapper wheel to dress it up.
2nd pic. Put the cup in place behind the knuckle.
3rd pic. Slide the shaft through the knuckle and cup.
4th and 5th pics. You got to push the CV joint into the cup. It a bear to do. you just got to get it started until you install the spindle.
6th pic. Lookin' through the bore.
7th and 8th pics. The spindle is installed. Now you can use something to pry the cup seal over the cv joint to seat the cup into place.

The thing I don't like about this is now there is a larger opening at the axle bore. With the stock axles, you had a flange at the opening to block any garbage from entering.
Attached Images
File Type: jpg 046.JPG (271.0 KB, 11 views)
File Type: jpg 047.JPG (278.1 KB, 9 views)
File Type: jpg 048.JPG (251.8 KB, 9 views)
File Type: jpg 049.JPG (269.8 KB, 10 views)
File Type: jpg 050.JPG (236.7 KB, 9 views)
File Type: jpg 051.JPG (211.7 KB, 8 views)
File Type: jpg 052.JPG (240.9 KB, 9 views)
File Type: jpg 053.JPG (258.0 KB, 11 views)

PWOC #53
2008 POWER WAGON RC
Sequentially Number #08-1505,
Inferno Red, Automatic
Mods to the PW;
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Extang Tonneau Cover, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, Had 35" Cooper STT's now 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper, PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal and it's own body bag!, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, MORE STUFF COMIN', TTI headers, Somebody's long arm, 7.2L MOTOR
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Mods to me; Ti hip replacement. Zerk fitting in knee. Now it's gets greased more than some guys front drive shafts. I've been Used, Abused and Recycled!
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Survivor of The Cold War,
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Heaven's Gate, The Grand Conjunction, The Pleiadeans Landings, Y2K, The Winch Mob Banning, The Mayan Apocalypse, and some other covert stuff. Future ISIS killer!
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"Moab '10, '12, '14",
"Rausch Creek-Spring, Fall '11, Spring '12, Summer '13, Summer '14"


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