tired_old_dave wrote:
Mine was bad right away. Selling dealership says they all weep. After enough had been thrown out, I went back and now they agreed with me. Mine has the 12.5K miles differential service requirement and it is trak-loc and towing package. At 12.5k, I did my own dif's front and rear. What I found in the rear was a milky brown dirty grease emulsion. The rear dif was not machined smooth on the bottom half only the top half with the old orange assembly material on it. I used an old machinist's brass brush to clean it off. Used the new grey rtv from dc, then two bottles of the new thin clutch lube(per jeep training info) and synthetic dc grease. I suspect that my Jan 05 build had some old rear installed before I got it, because I also had the "e-brake shoes grinding"? with no wearing of the rear pads against the rotors for these first 2k miles.
The muffler banging noise at idle was not the hangers in my case, it's the way the muffler section was installed. The muffler section has to be held up just right and the prevention of muffler banging the frame is accomplished by a unique amount of tightening of the two flange nuts. I fixed mine myself but it doesn't matter now because I saw retmil46's post and my better half and I got an aero-turbine for Christmas.
Glad to hear you can enjoy a good jeep in the open country.
Well, dave, you just paid back the favor. I read about your leaking pinion seals and checked mine. Sure enough, pinion seal on the rear diff has started slinging oil sometime recently. Pulled the plug and checked level, still pretty close to 1/2" below the hole, looks like I caught it just as it was getting started. Looks like a double header at the dealership, tranny TSB and rear pinion seal.