I agree this isn't somthing I am experianced enough to tackle on my own I am just trying to learn as much as I can about the differential and what maybe is wrong with mine before I listen to some mechanic telling me somthing is wrong that I know isn't, I am mechanically inclined but not enough to deal with inner gearing and specs etc,,,
I made a video of the inside of my unit yesterday and have a few idea's, I even went back to the shop and asked some question's still getting the same answer no idea on the cost to fix this, after close inspection the pinion gear and flywheel gear or what ever the big sproket is called looked fine, also the spider gears looked good, but I did notice the big pin that goes through the middle of the spider gear housing had play in it when i rocked it side to side, the mechanic said that isnt suppose to have play, I am thinking where the pinion seal is maybe the bearings have failed of the teeth of the pinion gear where is unseeable where the drive shaft goes in may be worn, there wasn't alot of metal shavings in the oil but was very small metalic pieces in the oil like glitter , I am not sure thats normal or if it's from the bearings , but like I said the gears seeable look fine not chewed up, and all seems to spin smoothly no grinding in there.
Just the same I guess there is a problem in there and simply resealing it isn't an option, I just need to figure where to take it that I know I wont be ripped off, doe's anyone have any idea if I bought a new axle what it generally cost to have that installed? I am not sure at my home I have the tools for that kinda job, seems I saw an axle online was 2 choices a 44 or 60 axle have no idea if the 60 is better or worth the price differance, but was like 2495.00 + 150.00 shipping, but the 60 axle was 2895.00+ shipping cost.
I guess I need to find out what my exact gearing is and if in fact whats in a 97 jeep wrangler sport is a Dana 44 , there's a # stamped into the differential cover maybe there's a way I can find out from that.
I spent over 1000.00 fixing alot of little thing's like the engine check light kept comming on saying P300< Random cylinder misfire, so I changed all the plugs and the ignition coil and spark plug wire's as well as several sensor's like the oil pressure and thermostate sensor, finally fixing the problem when i installed a new rotor in the distributor.
I put a cold air intake along with a throttle body spacer, next wanted to open up the exhaust with a flowmaster exhaust, but this differential problem stalled me on that along with new rims and tires I had lined up to be put on.(I also painted my bumpers and fendors with bumper black making the jeep look pretty darn good.) So after all my tinkering and improving on my jeep I am pretty bummed that I have this issue currently especially after I got it purring like a kitten and really improved the MPG a ton.
Anyway I thank everyone for their imput, I am still not giving up on my jeep will figure this out hopfully in a more cost effective way.