10.3 - Driveshafts¶
Both driveshafts are custom units built to measured length by Tom Woods Custom Drive Shafts after the drivetrain and suspension are mocked up at final ride height.2
Front Driveshaft¶
| Specification | Value |
|---|---|
| Type | Custom (Tom Woods Custom Drive Shafts) |
| Length | TBD #93 — measure at final ride height |
| U-Joint | TBD #93 — per Tom Woods build spec |
| Series | 1350 CV1 |
| Axle End | 1350 strap-style pinion yoke, 29 spline — see Front Axle |
Rear Driveshaft¶
| Specification | Value |
|---|---|
| Type | Custom (Tom Woods Custom Drive Shafts) |
| Length | TBD #94 — measure at final ride height |
| U-Joint | TBD #94 — per Tom Woods build spec |
| Series | 1350 CV1 |
| Axle End | 1350 strap-style pinion yoke, 31 spline — see Rear Axle |
| Transfer Case End | CV; rear pinion aimed at the transfer case output |
Outstanding Items¶
🔴 Critical (1)
- Rear 5.13 long-spline gearset (Revolution F10.25-513L) sourcing confirmation (#297) — There is no 10.5-native 5.13; the rear Sterling 10.5 runs the Revolution F10.25-513L (Ford 10.25" long pinion) with master kit 35-2046. Confirm availability and lead time with Revolution or a dealer before ordering the kit. A 2008-2010 donor housing also needs the SK F10.5-Conv pinion spacer (sold separately).
High (8)
- Re-spec 8HP70 → NP241OR adapter path (case changed from JK NV241 to TJ Rubicon Rock-Trac) (#313) — The transfer case selection changed from the JK NV241 GenII Command-Trac (2.72:1) to the TJ/LJ Rubicon NP241OR Rock-Trac (4:1) (owner decision, 2026-09-18 — deeper low range). All the adapter research on the transfer-case page was done against the JK case and does not carry over automatically.
- iBooster pedal ratio verification against 1.25" booster stroke (#301) — Verify the brake pedal ratio (approximately 4:1 per owner notes, 03-06 TJ/LJ auto pedal) against the Bosch Gen 2 iBooster's 1.25" stroke so the pedal reaches full booster travel without the cylinder bottoming, with the 1-1/8" Wilwood master and Super Duty calipers at all four corners. Bench-measure on assembly.
- ARB RD140 fitment with Revolution F10.25-513L in the Sterling 10.5 housing (#300) — The rear runs a 10.25" ring gear (Revolution F10.25-513L) in the 10.5 housing with the ARB RD140 carrier (Ford 10.25/10.5, 35 spline, all ratios). Confirm with ARB or Revolution that the RD140 flange and ring gear bolt pattern match the F10.25 gear in this housing before ordering, and confirm the pinion depth starting point (owner note: add roughly 0.120" to the pinion depth stack).
- Ball joint delete clearance against ORA high steer arms (#299) — Verify the American Iron ball joint delete (upper and lower, welded) clears the Offroad Anonymous 05-16 Super Duty Dana 60 weld-on full hydro high steer arms through full steering travel (40 degree target with the 8" PSC ram) and full suspension travel.
- Front axle ball joint delete bushing offset (0 / 1.5 / 3 degree) (#298) — American Iron ball joint delete bushing offset sets caster and camber together, summing to the bushing rating. Select after caster is measured with the Dana 60 under the vehicle at ride height. Every 15 degrees of bushing rotation gives 0.5 degrees of change on a 3-degree set.
- 4WD/4LO indicator — NP241OR position switch → PMU → HDX (measure switch at teardown) (#145) — Reversed 2026-09-18 — the 4WD indicator is wanted after all. (Previously closed as "omit the indicator.") Updated the same day for the transfer-case change from JK NV241 to TJ/LJ Rubicon NP241OR (#313), which makes this easier.
- Turbolamik Aux: P/N (#48) — Confirm aux output channel + pinout configured for P/N (start interlock)
- Turbolamik Aux: Reverse (#47) — Confirm aux output channel + pinout configured for Reverse signal -> PMU In 3
📋 Medium (9)
- ABS sensor opening plugs, front and rear axles (#310) — With no ABS on the build, the tone rings are omitted and the wheel speed sensor openings must be plugged. An unplugged opening in the rear housing is a gear oil leak path.
- Confirm ORA high steer kit quantity (per arm vs per pair) (#302) — Confirm whether the Offroad Anonymous 05-16 Super Duty Dana 60 weld-on full hydro high steer kit is sold per arm or per pair before ordering, so the purchase tracker quantity is right.
- Steering Cooler Fan (electrical) (#101) — On PMU Out 8 (~15A, 180F inline thermostat); confirm actual Mishimoto fan draw fits budget
- Steering Pump Specs (#99) — Kit pump PK40JP2-FH is Jeep 4.0L-only - source Cummins R2.8 PSC pump/bracket; flow/pressure/drive TBD
- Rear Suspension Components (#98) — Coil rate, bypass valving, control arms, track bar, sway bar
- Front Suspension Components (#97) — Coil rate, bypass valving, control arms, track bar, sway bar
- Rear Driveshaft Specs (#94) — Custom (Tom Woods) decided - measure length at final ride height & order
- Front Driveshaft Specs (#93) — Custom (Tom Woods) decided - measure length at final ride height & order
- Transmission Pilot Bearing (#91) — If required by flywheel/crank combination
📝 Low (2)
- Steering Reservoir & Fluid (#103) — Fluid = PSC/SWEPCO 715; remote reservoir (in pump kit) model/location + system fill qty TBD
- Suspension Geometry (#102) — Departure and breakover angles (calculated from chosen suspension)
Build Tasks¶
- Measure front driveshaft length at final ride height and order from Tom Woods
- Measure rear driveshaft length at final ride height and order from Tom Woods
Related Documentation¶
-
Owner build notes, 2026-09-16 — both shafts 1350-series CV from Tom Woods, matched to the 1350 strap-style pinion yokes on the Super Duty axles. ↩↩
-
Owner decision, 2026-05-30 — custom shafts sourced from Tom Woods Custom Drive Shafts; length and U-joint series are determined by Tom Woods from the measured working length at final ride height. ↩