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Old 05-30-2010, 03:33 AM   #1
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Need help. Rear axle overheating

Hi guy, I am new to this forum.

My rear axel on my TJ 96 is overheating and the oil is coming out of it. I changed the pinion, the spider gear, the O ring.I also tried 75, 90, 110 oil for it and it is still overheating at 80 degrees. This is a new problem. I rebuilt it 3 times with the same results. I have no idea of what to do.

Can someone help?

Thanks in advance.

Ian in Taiwan

TJ 96. 6" lift, 35" tires, ARB lockers, 4L engine,

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Old 05-30-2010, 03:36 AM   #2
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Well thats a weird problem, maybe its just filled too high? My buddys rear axle did that after he drove on the high way right after he filled it

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Old 05-30-2010, 03:36 AM   #3
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what rear axle do you have?
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Old 05-30-2010, 10:14 AM   #4
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I have the original one, not sure witch it is. I will re-build it tomorrow and let you know.
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Old 05-30-2010, 10:21 AM   #5
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What pinion angle are you running? Its not so high that you are starving the pinion bearing of oil?
Is it making noise? If the gear's are not set right that can create heat.
Taiwan Must have some great offroading any pics you are willing to share?
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Old 05-30-2010, 10:50 AM   #6
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Maybe it's time for a new axle? Not to slag your mechanic skills but perhaps you did something wrong in the rebuilds? That being said, the cost of multiple rebuilds could of bought you a new axle by now.
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Old 05-30-2010, 10:56 AM   #7
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1) How do you know it is "overheating"?

2) Where is the oil coming out of?

3) When you fill it, how do you know how much to refill it to?

Export TJs are normally built with a Dana 44 rear axle which is a very robust/strong axle.
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Old 05-30-2010, 10:59 AM   #8
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o-ring?
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Old 05-30-2010, 11:07 AM   #9
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o-ring?
Where is there an o-ring on a stock axle?
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Old 05-30-2010, 11:19 AM   #10
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Uhm, maybe I missed it, but what axle are we talking about here?

For the record, there were no 1996 wranglers...is yours a 95 (YJ - square headlights) or a 97 (TJ - round).

I'm voting for the overfill too...
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Old 05-30-2010, 12:48 PM   #11
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Sorry big mistake ( OUPS) I was talking about the rear differential. ( My bad)

-The oil is coming out of the ( I think the name is ) vacuum hose ( extended to go under water).

-Square lights.

-I know its overheating because I've got a temp gauge on the back one as well as the front one.

-My mechanical skills are not good (still learning as I go) but my friend has an off road shop and he is trying to help me as I go.

To all. I am new to the off road world. This is my first ever Jeep so, thanks for all your help and patience.

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Old 05-30-2010, 01:33 PM   #12
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Quote:
Originally Posted by rketr View Post
Uhm, maybe I missed it, but what axle are we talking about here?

For the record, there were no 1996 wranglers...is yours a 95 (YJ - square headlights) or a 97 (TJ - round).

I'm voting for the overfill too...
the last yjs that were exported were labeled as 1996 models

Quote:
Originally Posted by iix23 View Post
Sorry big mistake ( OUPS) I was talking about the rear differential. ( My bad)

-The oil is coming out of the ( I think the name is ) vacuum hose ( extended to go under water).

-Square lights.

-I know its overheating because I've got a temp gauge on the back one as well as the front one.

-My mechanical skills are not good (still learning as I go) but my friend has an off road shop and he is trying to help me as I go.

To all. I am new to the off road world. This is my first ever Jeep so, thanks for all your help and patience.

Here are some picks of my Jeep ( if it works)




There are more here.
Pictures by iix23 - Photobucket
that is a really nice jeep you got there.
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Old 05-30-2010, 03:32 PM   #13
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Jeeez. Talk about a rigged out jeep! Def survive a zombie attack w/ that!
That looks like a thousand pounds in accesseries!
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Old 05-30-2010, 08:34 PM   #14
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Jeeez. Talk about a rigged out jeep! Def survive a zombie attack w/ that!
That looks like a thousand pounds in accesseries!
Ha ha ha. You forgot the 400w wall of sound that is in the place of the back seat. ( show you some pics later).
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Old 05-30-2010, 08:40 PM   #15
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Quote:
Originally Posted by iix23 View Post
Hi guy, I am new to this forum.

My rear axel on my TJ 96 is overheating and the oil is coming out of it. I changed the pinion, the spider gear, the O ring.I also tried 75, 90, 110 oil for it and it is still overheating at 80 degrees. This is a new problem. I rebuilt it 3 times with the same results. I have no idea of what to do.

Can someone help?

Thanks in advance.

Ian in Taiwan

TJ 96. 6" lift, 35" tires, ARB lockers, 4L engine,
80 degrees?? wait, is this celsius? what temp is that in america

and it definitely looks like that axle is being overworked if its still a d35, that thing has some weight on it. make sure the vent isn't partially clogged letting pressure build up, and make sure its not overfull as already stated by others.
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Old 05-30-2010, 09:34 PM   #16
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lay-mans Celsius conversation

0 C = 32 F

20 C = ~70F

100 C = 212F

so 80 C is hovering right below 200 F
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Old 05-30-2010, 09:42 PM   #17
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so that didn't sound like "overheating" to me at first, and after just a quick search, under a load differentials will reach that temp. i wouldn't want mine sustaining that temp either though, but i see no need to be "rebuilding" your axle.

now i will stand by my previous statement, that axle is not up to the task you are giving it, you need to upgrade. secondly, what type of gear lube? synthetic gear lube has actually been proven to run hotter in differentials. and there is nothing wrong with moving to a 75/140 gear lube. that would be my first change.

my very quick web search gave me this impression: normal diff temps can be as much as 150-160, and people have reported 170-to as much as 220 towing. degrees Fahrenheit obviuosly. i would liken these conditions to a differential being used for towing.
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Old 05-30-2010, 10:02 PM   #18
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rear axle leak

I had the same problem on my 2000 tj with a dana 44 rear axle. Oil would leak out the vent tube after just a short drive. While installing the locker in the rear end, i found the race on the pinion bearing closest to the yoke was sitting crooked in the diff housing. It had some serious score marks in it. Replaced the pinion and carrier bearings and all is good so far. Good luck!
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Old 05-31-2010, 05:17 AM   #19
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Thanks for all your replies. I will get to the bottom of that story tomorrow as I have snapped the rear axle today. I didn't have any overheating problems with the differential.
I made a newbe error when I hit the gas to hard while the lockers were engaged. The back jumped and the wheels landed on the ground while they were spinning fast in the air.

OUPS, thank god my mechanics has tons on axles in his yard. Got a free pass on that one.
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Old 05-31-2010, 05:29 AM   #20
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just make sure a D35 doesnt go back under your jeep. those axles really cant take the abuse 35s and a locker put out.
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Old 05-31-2010, 06:19 AM   #21
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just make sure a D35 doesnt go back under your jeep. those axles really cant take the abuse 35s and a locker put out.
Any recommendations?
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Old 05-31-2010, 06:22 AM   #22
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ford 8.8 or a D44 would be ideal, but i dont know what you have access to in Taiwan.
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Old 05-31-2010, 06:28 AM   #23
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ford 8.8 or a D44 would be ideal, but i dont know what you have access to in Taiwan.
I will make sure to check that out. I know for a fact that D44 is available here in Taiwan.
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Old 05-31-2010, 06:33 AM   #24
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I will make sure to check that out. I know for a fact that D44 is available here in Taiwan.
cool. check which axle you have already. for all i know the export jeeps could have come stock with beefier axles.
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Old 05-31-2010, 08:03 AM   #25
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it looks good iix23

but i dont think a dana 35 is rated to move 12,000 pounds haha
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Old 05-31-2010, 09:10 AM   #26
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you will have never ending problems with that set up and that axle.
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Old 05-31-2010, 09:31 AM   #27
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you will have never ending problems with that set up and that axle.
Would you care to make a suggestion?
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Old 05-31-2010, 09:54 AM   #28
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as already stated., ford 8.8 and dana 44 are common upgrades.

it depends on what tire size you want, if you are staying with the set up you have, either one is a good choice. if you want bigger tires later, dana 60 or ford 9"
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Old 05-31-2010, 10:33 AM   #29
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as already stated., ford 8.8 and dana 44 are common upgrades.

it depends on what tire size you want, if you are staying with the set up you have, either one is a good choice. if you want bigger tires later, dana 60 or ford 9"
I already have 35" tires. Ford 8.8 and Dana 44 would be enough?
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Old 05-31-2010, 10:38 AM   #30
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Quote:
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I already have 35" tires. Ford 8.8 and Dana 44 would be enough?
if you plan on staying with 35 inch tires, then yes, a ford 8.8 or d44 would be good

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