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Jeep Wrangler YJ
YJ Build Threads & Member's Rides
1990 Jeep YJ "The Grey"
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<blockquote data-quote="dondons1984" data-source="post: 427236" data-attributes="member: 19097"><p>I found out the hard way with those diff bolts. I went and got grade 8 bolts and put them on. I think those bolts are just like head bolts sometimes cause with mine I broke off 3. I just got done doing a full rebuild on mine and swapped every single bolt and nut for better grade. If you can I’d do that. Yes it’s spendy but it is worth it especially those intake bolts. Those will freak you out along with your thermostat housing bolts. </p><p>All;</p><p></p><p>Decided to get some work on the Jeep done tonight. Wanted to fix this ridiculously annoying slow rear diff leak that has been staining my garage. I've been checking my fluid level every few days to monitor the rate. I also wanted to check the front diff health by checking the fluid level and quantity.</p><p></p><p>Went to AutoZone, grapped some 80w-90, red RTV, and am pumped to find a new black Jeep steering wheel cover to replace the one that is all torn up.</p><p></p><p>Got back home and pulled off the front diff fill bolt. I was very pleasantly surprised to find the fluid nice and clean and nearly topped off. Needed to add a little fluid but was pretty straight forward.</p><p></p><p>Went back to the rear diff, cracked it open, and was very very pleasantly surprised. The gear oil had very little metal shards in it and the gears looked to be in great shape. Below is a picture of it all opened up before any work.</p><p></p><p>[ATTACH=full]116021[/ATTACH]</p><p></p><p>I cleaned out the rear diff casing with some paper towels sprayed with some brake cleaner to get as much of the metal shards out as I could Below is a picture of my finger after wiping some of the oil out of the carrier and a paper towel which better shows the tiny metal particles. It is relatively normal for the first diff oil change after a regear to have pretty large chunks of metal as the gears which aren't perfectly manufactured kind of "grind" themselves to the norm so to speak. Mine had a pretty small amount of metal particles.</p><p></p><p>[ATTACH=full]116024[/ATTACH]</p><p></p><p>[ATTACH=full]116025[/ATTACH]</p><p></p><p>Began the process of cleaning up the mating surfaces which was the most time consuming part of this process. Tools I used include a brass and steel wire brush, brake cleaner, sanding pads, and finger nails. Found that brake cleaner followed by wire brush followed by sanding worked the best. Brake cleaner dried it up and dissolved it and the other two removed the RTV.</p><p></p><p>[ATTACH=full]116022[/ATTACH]</p><p></p><p>The axle was pretty awkward to clean up.</p><p>[ATTACH=full]116023[/ATTACH]</p><p></p><p>Used some Permatex Red RTV Gasket Maker. Shot for a 1/4 inch around the top of the cover and did double that on the bottom where leaks are more prevalent. Went back around the bolt holes as well. See below.</p><p></p><p>[ATTACH=full]116026[/ATTACH]</p><p></p><p>Once the RTV was applied, waited around 20 minutes for it to get tacky and hard. At this time I thought "wow, this is the first project on my YJ I've done where something hasn't gone wrong." Decided to spend the time and clean up the threads of the bolts a little bit.</p><p></p><p>[ATTACH=full]116027[/ATTACH]</p><p></p><p>Through the diff cover on, hand tightening the bolts and letting it sit for an hour.</p><p>I'm a fool in a man's shoes thinking this would go without anything going wrong. Tightened all bolts to 10 ft-lb no problem. Move up to 25 ft-lbs and, of course, I break a bolt. Ok. Cool. I move on and lower the torque to around 15 ft-lb and finish the job. I think I started to break another but stopped cause my heart couldn't take it. Of the 10 bolts on the cover I think 8 are effective. I have a trip planned to Big Bear tomorrow so I did the only responsible thing: I shoved a bunch of RTV into the hole! I'll deal with this problem in a few weeks. I'll be making sure to monitor the rear diff and its fluid level but I'm not overly concerned. If it has a rapid leak I won't go but any slow leak I'm still going to execute. I'm also snooping around for a Dana 44 rear so this 35 is really a temp axle for me. Below is a picture of the broken bolt before I filled it with ITV. Luckily both broken bolts are on top.</p><p></p><p>[ATTACH=full]116028[/ATTACH]</p><p></p><p>With this problem dealt with (for now) I started to work on another project. I've wanted some additional dedicated storage so ordered the Besttop rear tailgate organizer and bags. Easy install, self tapping screws, great instructions. 10/10 recommend. Below are some photos of the bags and them full of gear needed for the Big Bear wheeling trip this weekend.</p><p></p><p>[ATTACH=full]116029[/ATTACH]</p><p></p><p>[ATTACH=full]116031[/ATTACH]</p><p></p><p>[ATTACH=full]116032[/ATTACH]</p><p></p><p>[ATTACH=full]116030[/ATTACH]</p><p></p><p>Excited to keep adding on. Have a shade coming in, some new seatbelts, new leaf plates, and I'm still waiting for a new set of leafs with shocks. I'll continue to update this! Will post pictures of this weekend over on the wheeling trip thread.</p><p></p><p>Keep wheeling</p><p>Erik</p><p></p><p>[ATTACH=full]116016[/ATTACH]</p><p></p><p>[ATTACH=full]116017[/ATTACH]</p><p></p><p>[ATTACH=full]116018[/ATTACH]</p><p></p><p>[ATTACH=full]116019[/ATTACH]</p><p></p><p>[ATTACH=full]116020[/ATTACH]</p></blockquote><p>[/QUOTE]</p>
[QUOTE="dondons1984, post: 427236, member: 19097"] I found out the hard way with those diff bolts. I went and got grade 8 bolts and put them on. I think those bolts are just like head bolts sometimes cause with mine I broke off 3. I just got done doing a full rebuild on mine and swapped every single bolt and nut for better grade. If you can I’d do that. Yes it’s spendy but it is worth it especially those intake bolts. Those will freak you out along with your thermostat housing bolts. All; Decided to get some work on the Jeep done tonight. Wanted to fix this ridiculously annoying slow rear diff leak that has been staining my garage. I've been checking my fluid level every few days to monitor the rate. I also wanted to check the front diff health by checking the fluid level and quantity. Went to AutoZone, grapped some 80w-90, red RTV, and am pumped to find a new black Jeep steering wheel cover to replace the one that is all torn up. Got back home and pulled off the front diff fill bolt. I was very pleasantly surprised to find the fluid nice and clean and nearly topped off. Needed to add a little fluid but was pretty straight forward. Went back to the rear diff, cracked it open, and was very very pleasantly surprised. The gear oil had very little metal shards in it and the gears looked to be in great shape. Below is a picture of it all opened up before any work. [ATTACH type="full" alt="image14.jpeg"]116021[/ATTACH] I cleaned out the rear diff casing with some paper towels sprayed with some brake cleaner to get as much of the metal shards out as I could Below is a picture of my finger after wiping some of the oil out of the carrier and a paper towel which better shows the tiny metal particles. It is relatively normal for the first diff oil change after a regear to have pretty large chunks of metal as the gears which aren't perfectly manufactured kind of "grind" themselves to the norm so to speak. Mine had a pretty small amount of metal particles. [ATTACH type="full" alt="image13.jpeg"]116024[/ATTACH] [ATTACH type="full" alt="image12.jpeg"]116025[/ATTACH] Began the process of cleaning up the mating surfaces which was the most time consuming part of this process. Tools I used include a brass and steel wire brush, brake cleaner, sanding pads, and finger nails. Found that brake cleaner followed by wire brush followed by sanding worked the best. Brake cleaner dried it up and dissolved it and the other two removed the RTV. [ATTACH type="full" alt="image11.jpeg"]116022[/ATTACH] The axle was pretty awkward to clean up. [ATTACH type="full" alt="image10.jpeg"]116023[/ATTACH] Used some Permatex Red RTV Gasket Maker. Shot for a 1/4 inch around the top of the cover and did double that on the bottom where leaks are more prevalent. Went back around the bolt holes as well. See below. [ATTACH type="full" alt="image8.jpeg"]116026[/ATTACH] Once the RTV was applied, waited around 20 minutes for it to get tacky and hard. At this time I thought "wow, this is the first project on my YJ I've done where something hasn't gone wrong." Decided to spend the time and clean up the threads of the bolts a little bit. [ATTACH type="full" alt="image9.jpeg"]116027[/ATTACH] Through the diff cover on, hand tightening the bolts and letting it sit for an hour. I'm a fool in a man's shoes thinking this would go without anything going wrong. Tightened all bolts to 10 ft-lb no problem. Move up to 25 ft-lbs and, of course, I break a bolt. Ok. Cool. I move on and lower the torque to around 15 ft-lb and finish the job. I think I started to break another but stopped cause my heart couldn't take it. Of the 10 bolts on the cover I think 8 are effective. I have a trip planned to Big Bear tomorrow so I did the only responsible thing: I shoved a bunch of RTV into the hole! I'll deal with this problem in a few weeks. I'll be making sure to monitor the rear diff and its fluid level but I'm not overly concerned. If it has a rapid leak I won't go but any slow leak I'm still going to execute. I'm also snooping around for a Dana 44 rear so this 35 is really a temp axle for me. Below is a picture of the broken bolt before I filled it with ITV. Luckily both broken bolts are on top. [ATTACH type="full" alt="1image4.jpeg"]116028[/ATTACH] With this problem dealt with (for now) I started to work on another project. I've wanted some additional dedicated storage so ordered the Besttop rear tailgate organizer and bags. Easy install, self tapping screws, great instructions. 10/10 recommend. Below are some photos of the bags and them full of gear needed for the Big Bear wheeling trip this weekend. [ATTACH type="full" alt="1image6.jpeg"]116029[/ATTACH] [ATTACH type="full" alt="1image2.jpeg"]116031[/ATTACH] [ATTACH type="full" alt="1image1.jpeg"]116032[/ATTACH] [ATTACH type="full" alt="1image0.jpeg"]116030[/ATTACH] Excited to keep adding on. Have a shade coming in, some new seatbelts, new leaf plates, and I'm still waiting for a new set of leafs with shocks. I'll continue to update this! Will post pictures of this weekend over on the wheeling trip thread. Keep wheeling Erik [ATTACH=full]116016[/ATTACH] [ATTACH=full]116017[/ATTACH] [ATTACH=full]116018[/ATTACH] [ATTACH=full]116019[/ATTACH] [ATTACH=full]116020[/ATTACH] [/QUOTE] [/QUOTE]
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YJ Build Threads & Member's Rides
1990 Jeep YJ "The Grey"
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