Shot intermediate shaft?

[RenKJ]

Is my intermediate shaft shot? Or does this extending out mean my differential could be damaged? I'm assuming I need to replace intermediate and cv on this side?

Checking if people can advise what I'm in for

Is my diff likely empty of gear oil?

 

[DadOSix]

I am doing this very thing, while replacing the right side ball joints. I have known the shaft seal was leaking, but it was a ‘get to it someday’ thing. Now, I had the knuckle off and pulled the cv axle, because, why not —- The inner boot was torn when the jeep came down after the ball joint failed.

Anyway, a groove is worn (ground) into the shaft and the housing is dry as a bone in the axle tube. I had planned on replacing the bearing and seal while the cv shaft is out, but now need to find either a replacement intermediate shaft - or - an offset bearing that would allow the damaged intermediate shaft to be used, but the bearing sits back about 3/4 inch from the damaged area.

We used to do this years back on rear axle applications, but I can not find a mention of the repair bearing for this application.

 

[DadOSix]

Is my intermediate shaft shot? Or does this extending out mean my differential could be damaged? I'm assuming I need to replace intermediate and cv on this side?

Checking if people can advise what I'm in for

Is my diff likely empty of gear oil?

- if it is dry, count on the shaft being damaged. There is a good parts diagram on Crown Automotive that shows the exploded view, but no prices as they sell only to ‘trade (pro shops) accounts’.

So - plan on the cv, intermediate, bearing, seal.

If you have never had it down this far, you will need to remove the clevis from shock and lower control arm to allow the cv shaft to come thru.

 

[KJowner]

- if it is dry, count on the shaft being damaged. There is a good parts diagram on Crown Automotive that shows the exploded view, but no prices as they sell only to ‘trade (pro shops) accounts’.

So - plan on the cv, intermediate, bearing, seal.

If you have never had it down this far, you will need to remove the clevis from shock and lower control arm to allow the cv shaft to come thru.

I wonder if you could just insert a spacer between the bearing and seal to move the seal out a fraction to give it a new surface to run on?
The other thing worth a look is a speedy sleeve to recover the surface.