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  1. #1
    Wagonist mr_sp33's Avatar
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    RT4wd EF carrier bearings / center bearings / driveline vibration SOLVED

    Hi Everyone.

    As anyone who owns an RT4wd wagon is probably aware, driveline vibrations are the devil. Luckily Rockford Driveline came to the party and now sell replacement U joints (430-10C is the part number), however that only solved part of the problem.

    First, a bit of an explanation of what's going on. This 3 piece prop shaft is designed to be inline, where there is no designed angle of the U joints. Over time, this causes the needle bearings inside the caps of the U joint to wear a notch on the point where they spend all of their time positioned. This isn't a big deal, until you consider that the carrier bearing housings also sag over time, or in more extreme cases can tear. This creates an angle at the U joint, which means the u joint no longer spends all of its time on center, instead it 'pops' in and out of its worn center position and creates a nasty vibration. Also if the center bearing has sagged to the point where it's no longer suspended by the rubber (instead the inner section is touching the outer section) then the vibrations become much more noticeable.

    Here's an example of a worn out carrier bearing housing:



    So there's two things here. Replace the U joints to remove the worn needle bearings, and replace the carrier bearing housing to re align your prop shaft angles. Unfortunately your only option for the carrier bearing housing was to find another used less clapped out example, now you have the choice to instead buy a set of these:







    I made a set for myself, and they work great. A direct bolt on replacement.









    Parts a still a couple of weeks away from being assembled, so you can't buy a set just yet. At this stage i'm going to be making 10 sets of 2 pending additional interest.

    Pricing will be 240 USD + shipping/fees for a replacement set of 2. This includes the replacement bearing+retainer and housing.

    Please let me know any comments, or questions.

    ******UPDATE******

    I am now taking pre orders. There are currently 10 sets available. To gaurantee your set please pm me with your shipping address, and i'll get you a total price. Payment to be made upfront by Paypal, buyer to cover fees.

    1 - zcpowereddx (DSO) (shipped )
    2 - OneBadRT4WD (HCW) (shipped )
    3 - truckslammer (HCW)
    4 -
    5 -
    6 -
    7 -
    8 -
    9 -
    10 -
    Last edited by mr_sp33; 1 Day Ago at 11:02 PM.
    EF5 4WD DOHC ZC + JRSC

  2. #2
    Moderator superhatch's Avatar
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    I'm in. Let me know about payment.
    "It's very difficult to present technology as an overtly positive sales device to people who want an emotional car" -Chris Harris
    My Wagon Blog
    My Civic Si Blog

  3. #3
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    I am in as well. Do you have any clue how much shipping would be to the United States? I know things can escalate quickly with customs / duties / etc.

  4. #4
    Wagonist mr_sp33's Avatar
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    Shipping to the US will be approx 60$.

    I'll update this post with payment details when they're in stock and ready to ship.

    Thanks for the interest!
    EF5 4WD DOHC ZC + JRSC

  5. #5
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    I am interested as well. Great work!
    88 WAGO MF !!!!

  6. #6
    Wagonist
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    I would def be in on a set as well. I am pretty sure mine are worn as well. Please update when available. Thank you for making this effort!
    89 Blue RT Auto
    All stock
    DaPics!



  7. #7
    Wagonist mr_sp33's Avatar
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    First batch of the CNC'd center housing arrived on Friday:








    Still waiting on a couple more bits but they're coming along...
    EF5 4WD DOHC ZC + JRSC

  8. #8
    Moderator superhatch's Avatar
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    Yay! Love to see innovation for the wagons. This is a great thing you're doing for the community and I for one am super excited!
    "It's very difficult to present technology as an overtly positive sales device to people who want an emotional car" -Chris Harris
    My Wagon Blog
    My Civic Si Blog

  9. #9
    Wagonist
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    Super cool!
    89 Blue RT Auto
    All stock
    DaPics!



  10. #10
    Wagonist mr_sp33's Avatar
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    Last of the parts are in. Time for assembly


    EF5 4WD DOHC ZC + JRSC

  11. #11
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    Awesome! Looking good man!

  12. #12
    Wagonist mr_sp33's Avatar
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    Please see first post for UPDATE. Due to the amount of interest, I'm now taking pre orders so people can guarantee their set.

    Also, housing assembled... Off to powdercoat next:

    EF5 4WD DOHC ZC + JRSC

  13. #13
    Band Wagon
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    PM sent, let's do this!!!

  14. #14
    Wagonist
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    PM sent for shipping quote~
    89 Blue RT Auto
    All stock
    DaPics!



  15. #15
    Wagonist mr_sp33's Avatar
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    Pm's replied
    EF5 4WD DOHC ZC + JRSC

  16. #16
    Wagonist mr_sp33's Avatar
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    Another set sold, post updated.
    EF5 4WD DOHC ZC + JRSC

  17. #17
    Wagonist mr_sp33's Avatar
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    Outer housings back from powdercoat:

    EF5 4WD DOHC ZC + JRSC

  18. #18
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    Pm sent! Please check inbox!

  19. #19
    Wagonist mr_sp33's Avatar
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    Quote Originally Posted by Thefakecaleb View Post
    Pm sent! Please check inbox!

    No probs, i've sent you a PM.
    EF5 4WD DOHC ZC + JRSC

  20. #20
    Wagonist mr_sp33's Avatar
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    Updates:


    My vacuum degassing chamber arrived. Set it up and had a go and worked good. This is to remove some small bubbles i was noticing that rose to the surface of the prototype ones i did early on while it was setting.





    Couple of pics of it pulling bubbles out of the urethane:








    I've got a retaining ring that needs to be welded to the CNC'd inner housings which has been delayed (was hoping to get them done this weekend, but the tooling broke unexpectedly and i'm getting them laser cut instead).


    So casting will start this time next week instead of this weekend as expected.


    Apologies guys!
    EF5 4WD DOHC ZC + JRSC

  21. #21
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    No problems on the delay; I would rather have them right than have them quick!!! I am happy to see a vacuum chamber being used, that was actually a concern of mine. Top notch work mate!

  22. #22
    Wagonist mr_sp33's Avatar
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    While we're waiting patiently i thought i'd post up some photos of the R&D that went into selecting the right urethane compounds and bonding agents.

    If you're not aware, polyurethane will bond to just about anything, but the quality of the bond depends on a lot things. Through trial and error and getting feedback from various companies tech staff, I've managed to achieve a bond that exceeds the strength of the polyurethane.

    Of course, this is only part of the design. Both the inner and outer housings are overmolded in such a way that they both have mechanical bonds which also secure the molded urethane to each housing.







    The first two images show a less successful bond, where the urethane is stronger than the adhesion which means it can be delaminated by pulling it off. The last image shows the bond strength is better than the urethane and can not be removed without destroying the urethane. This was achieved by careful surface prep of the steel, a bonding primer, a bonding agent and then laying the urethane over the top.
    EF5 4WD DOHC ZC + JRSC

  23. #23
    Wagonist mr_sp33's Avatar
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    I've got everything now and have started casting.

    Here's number 1:





    The urethane takes about a day to set enough to de mold, so i'm casting about 1 per day from now. First 2 sets to be shipped next Monday, and the third a couple of days after that.

    Watch this space
    EF5 4WD DOHC ZC + JRSC

  24. #24
    Council Member bam-bam's Avatar
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    Nice work, man. I stay away for a couple years, now look what you guys are into!

  25. #25
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    Awesome!!! Still looking good! They almost look too good to put on the car haha!

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