FAD Clunk and easy upgrade.

[DOOKEY]

Had my 392 for 4 weeks and have noticed a clunk in the FAD since I picked it up used. I'd pull into the garage and park. When leaving I'd reverse out of the garage and when the front axle loads up I kept hearing a clunk so I set to work. Pulled the stock inspection plate and noticed the stock FAD collar had an excessive amount of slop on the splines. You could feel it rotating quite a bit which would make sense that the collar was twisting a bit on the splines when changing directions. I drained the fluid and cleaned everything up first. Installed new fluid and the clunk still remained. Did some reading on this forum and found a FAD delete/spacer kit from Spicer. The replacement collar is much wider than the stocker so it make sense the rotational click could be reduced. I bought it from @Northridge4x4 and had it a day later. THANKS AGAIN!!

Link:
https://www.northridge4x4.com/part/10045078-dana-spicer-fad-removal-spacer-kit

Ripped out the old part last night and so far the clunk is gone. Easy update to an annoying problem that gives me a little more confidence in that area.

This thread is to add info for others who might have this issue in the future. There are plenty of FAD related knowledge but only a little I could find regarding this replacement kit.

Nice color! ?

Part number for later.

New spacer test fit. I tried everything I could to pull those stock pins out with some pliers but they just weren't budging so I had to grind them flat.

Much more spline engagement. Considerably less twist in the collar now that there is more engaged.

Shoulda painted my bolts black.?

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[stumblinhorse]

Inside the FAD cover on a 392 is new territory for me. So quick question, did you pull a front axle shaft to install this? Looks like a good upgrade. Nice work.

 

[Terpsmandan]

Please elaborate. There does not seem to be any instructions available on the interweb. I haven't heard the clunk yet but diesels don't only come with the PT 4x4 t-case.

 

[DOOKEY]

Inside the FAD cover on a 392 is new territory for me. So quick question, did you pull a front axle shaft to install this? Looks like a good upgrade. Nice work.

The FAD cover on the 392 is unique in the JL platform. My 18 and 19 have the functional FAD motors so it still disconnects to provide the FAD function. The 392 FAD cover has a cast "shift" fork that doesn't move. It just holds collar in place to keep the mid shaft and outer shaft locked together.

In order to do this upgrade you have to remove the CV portion only to remove the stock collar and install this beefier unit. So removal of all the parts on the knuckle have to come off as well. Took about an hour with my trusty impact.

 

[DOOKEY]

Please elaborate. There does not seem to be any instructions available on the interweb. I haven't heard the clunk yet but diesels don't only come with the PT 4x4 t-case.

Any FAD could develop the clunk. What came in my axle was a bunch of sloppy parts. The collar inner splines were very loose on both stock shaft sides. It happens. The best solution if you want to remove the FAD function is a solid 1 piece inner shaft. Less moving parts means less chance for failure. I'm 95% sure these stock axles won't stay under my Jeep so this fix was a process of elimination and instead of spending the money on replacement shafts I can understand better what's going on with this axle.

 

[firedude]

Thanks for the heads up.

 

[Bronson90]

thanks! do they make a full non-fad stock axle for the 392?

 

[DOOKEY]

thanks! do they make a full non-fad stock axle for the 392?

Yes. There are replacement 1 piece shafts. Spicer makes a set and so does RCV.

 

[Bronson90]

Yes. There are replacement 1 piece shafts. Spicer makes a set and so does RCV.

Any chance you have a spicer part number? I can just replace the passenger side or do I have to replace both?

Thanks in advance!

 

[DOOKEY]

Any chance you have a spicer part number? I can just replace the passenger side or do I have to replace both?

Thanks in advance!

10044459 is both front shafts in chromoly.


https://www.northridge4x4.com/part/...nscDrUwWVPCwv0j8UexNgEbdGTiiKLrhoClqMQAvD_BwE


You can replace 1 side only but in theory you should replace both sides at the same time. It's better to match alloys and joints so you aren't creating a weak point.

 

[BadA$$Rubi]

Yes. There are replacement 1 piece shafts. Spicer makes a set and so does RCV.

Just to add my 2 cents worth and to my knowledge, the Dana Spicer is NOT a 1-piece passenger axle design. Only RCV offers that design.
Dana Spicer’s kit is designed as a FAD DELETE System that couples the passenger axle to the intermediate axle. The axle kit 10044459 you listed does not include the FAD Removal kit. The FAD Removal Kit: 10045078 can be purchased separately, which includes a splined coupling and other miscellaneous parts.
There is a complete Front Axle Kit 10044474, that includes axles and FAD Removal Kit.

 

[Jtphoto]

Thank you for posting this. Going through the same things but more to get ride of the computerized FAD not engaging my FAD.

 

[Bzinsky]

I thought the 392 does not have a FAD? This is news to me.

it doesn’t have 2wd so what’s the point?

edit:nm I saw the explanation above

 

[DOOKEY]

I thought the 392 does not have a FAD? This is news to me.

it doesn’t have 2wd so what’s the point?

Trying to keep the rear axle alive. ?

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