Is this too much intermediate shaft play?

[HoosierJeeper]

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Trying to diagnose a vibration and popping noise I'm getting.

 

[tommudd]

Hard to tell for sure, but sure looks like more than normal for sure

 

[JeepJeepster]

Mine didnt have much play at all when it was making popping noises. Almost sounded just like a bad CV joint and only did it at low speeds, normally when turning. Heck it mightve been a bad CV since I replaced them at the same time but the Jeep had less than 60K miles on it I think. I recently took it all apart and greased it good, splines still looked brand new. I replaced it in 2008 I reckon. If chrysler had only put a dab of grease in there.

Had my, at the time, very inexperienced mind confused and I didn't want to spend a bunch of $$ on it. I never did get them apart.... Even tried using a come-along and chained it to a tree. Cranked it down hard and smacked it with a sledge hammer, no go.

 

[LibertyTC]

That is a lot of slop going on there HJ.
My Jeep Was Hot & crawled under & it was super tight !

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I'll quote Bob from link below:

You may be forced to change the intermediate shaft which connects the passenger side CV axle to the diff. It's not unusual for the CV to be rusted to the intermediate shaft so you can't get them apart - best to order the shaft and the CV together.
Bob

https://www.jeepkj.com/threads/how-to-change-a-front-cv-axle.44548/

 

[first&lastKJ]

My 07 had less slop than yours does. I was getting a random vibration at different speeds and it would come and go. I did not have any kind of popping sound though. I replaced the intermediate shaft and CV axle that solved my problem.

 

[HoosierJeeper]

The new intermediate shaft doesn't want to lock into the diff, anyone had an issue with that? I didn't try tapping it in yet. Could the c clip be too open? Once the CV is attached, I can just pull the whole thing out of the diff.

 

[tommudd]

Takes a few whacks at times to get the intermediate shaft to pop back in,
lube it up some ( little bit ) sometimes helps
I've fought a couple of them and they finally just popped back it easily

 

[HoosierJeeper]

Just hit it on the end? Here's the c-clip on it...

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[tommudd]

With small amount of grease go around the clip, center it the best you can with the grease holding it in place
Then wack - a - mole !
works 99% of the time

 

[HoosierJeeper]

Does that clip look normal? It's just weird, I can get it in place and it looks normal, it feels like it seats in to the right spot, but then it just pulls out with the cv attached.

 

[JeepJeepster]

Make sure you put plenty of grease between the cv and the shaft!

Shove it home and be done. I normally need to use a small pry bar to pop mine out though.

 

[HoosierJeeper]

Look at the difference between the older intermediate shaft (left) and the new one (right)...the part past the snap ring groove is longer and the end is more domed. The old one is more flat.

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[JeepJeepster]

Thats interesting. That longer part may be keeping it from engaging.

Where did you get it?

 

[HoosierJeeper]

eBay, Crown brand... I always thought Mopar, Crown, Omix-Ada was all the same for these but maybe not.