JL Dana M210 Hybrid Build (Willys + Rubicon) – Intermediate Shaft “Ring” Damage / Fitment Question

[alston05]

Working through a front axle rebuild and ended up with a bit of a hybrid setup. Looking for some input from anyone familiar with the M210/FAD internals.

Base vehicle is a 2024 Willys with a damaged front axle housing and missing intermediate shaft. For the rebuild, I picked up a 2018 JL Rubicon front axle and am mixing components as follows:

• Rubicon: housing, intermediate shaft, 4.10 gears (FAD axle)
• Willys: driver-side and outer passenger-side CV shafts
• Running the Willys factory FAD delete (fixed fork on plate/box cover)

On the intermediate shaft (Rubicon), there is a ring/bushing around the opening where the passenger outer shaft interfaces. On mine, about 40% of the outer lip of that ring is broken off. The inner bore looks intact.

Questions:

1. What exactly is that ring (guide bushing/seal?), and is it critical to operation or just for alignment/support?
2. Is that piece serviceable on its own, or does it require replacing the intermediate shaft assembly?
3. On the passenger outer shaft, the inner stub engages into the intermediate shaft but will not fully bottom out. It does engage far enough to be captured by the coupler. Is that normal for these, or should it fully seat?

Trying to determine if I’m good to run it as-is or if I need to replace the intermediate before buttoning everything up.

Appreciate any insight.

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