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Unread 06-29-2010, 10:04 PM   #316
Bama_WJ
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Just got done putting another brand new rear output seal and brand new lock ring on my 242. STILL LEAKS! The seal was gone within the first 10 minutes of driving easy. And I'll venture to say this is the worst its been. I can see a faint cloud of ATF behind me when I'm going down the highway. My rear hatch and bumper have a film of ATF all over. This is really starting to piss me off. The only thing I can think of that I'm doing wrong is putting the seal on wrong. I remember seeing something a tad off on the one I put on today and thought that was just the way it was suppose to be. But from looking at my old one, the inner lip on the seal must get caught in the lock ring groove. Going to get 2 more seals from NAPA tomorrow.

On a side note, put the first bit of color on my diff cover. Looks pretty nice.

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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

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Unread 06-29-2010, 11:47 PM   #317
TX-WJ
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Can't remember if you mentioned this or not, but did you check the vent on the TC and make sure it's not clogged up or sumnt, causing the leak on your output seal time after time......nawmsayin'.
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Unread 06-30-2010, 01:02 PM   #318
tennesseewj
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I'm sure you're already doing this, but I'll say it just to be safe.

Make sure you lube the inside of the seal with ATF before pushing it on, it will help keep it from getting snagged.

Other than that I don't know, mine went on once and was fine.
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Unread 06-30-2010, 04:16 PM   #319
Bama_WJ
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Quote:
Originally Posted by TX-WJ View Post
Can't remember if you mentioned this or not, but did you check the vent on the TC and make sure it's not clogged up or sumnt, causing the leak on your output seal time after time......nawmsayin'.
Yea, got that covered. Replaced it already. Got enough to route all the way to the top of the master cylinder.

Quote:
Originally Posted by tennesseewj View Post
I'm sure you're already doing this, but I'll say it just to be safe.

Make sure you lube the inside of the seal with ATF before pushing it on, it will help keep it from getting snagged.

Other than that I don't know, mine went on once and was fine.
Actually, I haven't been doing that. I know now that I should have put something on it, so it's a lesson learned. I'll be doing that tomorrow.
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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

North Alabama Jeep
42RE Vent Mod - Seal your transmission!
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Unread 07-01-2010, 11:37 PM   #320
Bama_WJ
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Gave it another go at a new seal today. I was pretty determined not to let it defeat me again. But I figured out why it was failing every time. Turns out when I put a new seal on the spring came off the seal whenever I tried to shimmy it around that lock ring groove. So in essence, the seal was useless the second I put it on. Decided to bring up the FSM to see how the dealership put a new one on. Turns out they have a special tool that creates a smooth surface all the way to where the seal sits (found here: SPX Miller Special Tools | Detail: 6992 - PROTECTOR, SEAL). Its pretty nifty, but not enough for $66.

The solution? Using my genius, I put a piece of electrical tape around the lock ring groove and dabbed some grease on it. The seal went on WAY easier and now my leak is cured. The only thing good to come of this fiasco was seeing my undercarriage the cleanest its ever been.

About the diff cover, I have one more coat of clear to put on it and it will be done. Some parts of it seriously look like they are powder coated. Its turning out nice!
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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

North Alabama Jeep
42RE Vent Mod - Seal your transmission!
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Unread 07-02-2010, 09:47 AM   #321
tennesseewj
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That is a tricky little tool for the seal. Glad to see that you were able to get by without having it.


I can already tell you the diff cover looks terrible. Send it to me and order yourself a new one.
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Unread 07-02-2010, 07:16 PM   #322
Bama_WJ
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Quote:
Originally Posted by tennesseewj View Post
I can already tell you the diff cover looks terrible. Send it to me and order yourself a new one.
Nice try.

Going out to put the last coat of clear on it now. Will have a pics and a mini write up on it when its finished.
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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

North Alabama Jeep
42RE Vent Mod - Seal your transmission!
YouTube. - My Video Channel
Facebook - Wheeling Pictures/Videos
The Jeep Wave. Bringing it back.
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Unread 07-04-2010, 02:35 PM   #323
Bama_WJ
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Just finished up installing my BTF 44a cover on the Jeep. It looks really nice.

Here is what I started out with:



I used a mixture of Rustoleum and Dupicolor prodcuts:



Hit it with the primer then sanded (repeated 2x):



My "paint booth". It worked pretty good!



Started off painting the fill plug black:



Then moved on to the first coat of the Duplicolor:



After about 4 coats of the Duplicolor:



After the color, I threw some clear on it. A few minutes after spraying down the clear, I placed the cover in the oven at 170º for about 10 minutes. Gave it a nice glossy coat:



Finished product (side note: the fill plug is a 14mm hex and the 10 cover bolts are 6mm hex for anyone interested in buying this cover):





The Duplicolor paint I got said it was suppose to match factory colors. I think they did pretty good:



Comparison to the stock cover. The diff took nearly 3 quarts of fluid with the new cover on.





And finally, pictures of it installed:







I think it looks great back there.
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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

North Alabama Jeep
42RE Vent Mod - Seal your transmission!
YouTube. - My Video Channel
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Unread 07-04-2010, 02:41 PM   #324
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Frickin sweet.




The next food cooked in the oven might taste funny though
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You need to learn, there are 3 things that all JF members must like beside Jeeps:
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I was bored so I forded the river. No oxen were lost.
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Unread 07-04-2010, 02:54 PM   #325
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Looks damn good daniel, damn good. Id be surprised if that started to chip.

Do all WJ owners take their rear sway bar off or something? Or did you just have to take yours off to put it on. Cause my rear has like 0 flex lol
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Unread 07-04-2010, 03:05 PM   #326
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that thing looks amazing!
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Unread 07-04-2010, 03:32 PM   #327
Bama_WJ
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Quote:
Originally Posted by tennesseewj View Post
Frickin sweet.




The next food cooked in the oven might taste funny though
Thanks. The taste of working on my Jeep. Yumm.

Quote:
Originally Posted by MoonyJohn View Post
Looks damn good daniel, damn good. Id be surprised if that started to chip.

Do all WJ owners take their rear sway bar off or something? Or did you just have to take yours off to put it on. Cause my rear has like 0 flex lol
Thanks man. Mine has been off ever since I swapped in the 44a. The bolts on the IRO end links I had always kept coming undone, so I just said eff if and left it off when the 35 came out.

Quote:
Originally Posted by lateralus3 View Post
that thing looks amazing!
Appreciate it!
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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

North Alabama Jeep
42RE Vent Mod - Seal your transmission!
YouTube. - My Video Channel
Facebook - Wheeling Pictures/Videos
The Jeep Wave. Bringing it back.
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Unread 07-04-2010, 03:35 PM   #328
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Looks damn good daniel, damn good. Id be surprised if that started to chip.

Do all WJ owners take their rear sway bar off or something? Or did you just have to take yours off to put it on. Cause my rear has like 0 flex lol
With the BTF cover you have to take it off because it hits the cover. I think there is a spacer you could buy, but the jeep runs just fine without it..most don't bother to put it back on. As far as flex goes the WJ has really good flex with the stock bar on, you don't have an addco rear bar do you? thats the only reason I could see the WJ rear not flexing good.
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Unread 07-09-2010, 03:05 PM   #329
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That 44a is all done now. Looks good.

I'm hitting up stoney lonesome tomorrow if you want to go.
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Unread 07-09-2010, 04:27 PM   #330
Bama_WJ
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Quote:
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That 44a is all done now. Looks good.

I'm hitting up stoney lonesome tomorrow if you want to go.
Not quite done yet. Thinking about throwing some good axles in there soon.

Dang, Stoney Lonesome tomorrow is tempting. Short notice though. Probably won't make it out tomorrow. I'll probably be helping my buddy get his Honda back in action for ImportAlliance in about a week. Motor ain't even in the car yet.

However, I'll probably be heading down to Gardendale for some wheeling on the 24th. JJaminson was telling me about it. Sounds like it will be a fun time. Maybe he will chime in about it.
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1 Ton WJ Build In Progress

The Daily: 2011 Chevy Cruze Eco - Trifecta tuned and 37+ MPG

Wife's Jeep: 2006 WK Overland - OME HD Lift, 265/70/17 BFG AT's, 1.25" SpiderTrax wheel spacers, 3" Gibson Cat-Back

North Alabama Jeep
42RE Vent Mod - Seal your transmission!
YouTube. - My Video Channel
Facebook - Wheeling Pictures/Videos
The Jeep Wave. Bringing it back.
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