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That’s a crack or manufacture flaw. Glad you replaced them !! Sent from my iPhone using Jeepz.com mobile app

Still too cold to get started on this. Pix to come when I do. Sent from my iPhone using Jeepz.com mobile app

Interesting. Mine an a 5 speed manual. Sent from my iPhone using Jeepz.com mobile app

will def be replacing rms !! Since this is a pre '99, this doesnt have the dual cats they used in 2000+ models. I only have one cross pipe from exhaust..... I watched a bunch of vids, mostly for 2000+ and i wouldnt wish that on anyone.

It’s possible. After watching numerous vids I’m going with either piston skirt issue or rod bearing. It is only #1 cyl with this issue which is common. I plan on rod bearings in any case but if it is a piston issue then I’ll replace all six in-engine. Ugh. There was an TsB issued in the 90s...

PS. THIS IS A TJ Sent from my iPhone using Jeepz.com mobile app

So one morning engine had a terrible knock. Out of nowhere really. Never heard it before. 266.6k miles on it. Man trans. I tried the mystery oil no avail. What I finally learned is that the rear main seal has been leaking. Enough over time to drain my capacity down 2.5 qts before I found this...

Had to put new turn signal switch in my 97 tj 4.0. About a 20 min swap. The plastic “switch” cancel on the switch was cooked. Glad it wasn’t the cam on the steering column. Ugh. Sent from my iPhone using Jeepz.com mobile app

Was there any performance improvement as well? I put on a 1” throttle body spacer and runs nicer now. 4.0 EFI. Sent from my iPhone using Jeepz.com mobile app

Update on the issue of why pin was not right sized. The landing on the new side gears was shallower than the original side gears meaning the C clips wouldn’t seat far enough in the gear so they stuck out enough to prevent the pin from clearing the axle ends. Sent from my iPhone using...

I didn’t see any further on your post other than the one sentence. However. I did shave down the C clips by 15 thousands on each one and pin went in fine. Its all back together now and its running on the 500 mile break in. Finally!!! Done!!! No noise no clicking no anything...

I did find an article about the same issue from 2000. Seems the axles are not seating all the way in the gears although it sure appears that way. Could be the new side gear washers are too thick and one guy says pry the axles outwards. He swears by it. So…..I’ll update later. Sent from...

Hahahaha Sent from my iPhone using Jeepz.com mobile app

The pin on the original came out loose and is the same diameter which also has the same problem. The new carrier gears ate one less tooth than the originals but fit fine into the new replacement carriers. Seems the axle with a clip on it doesn’t sit back far enough into the side gears and...

Well. One more headache ?? The carrier pin won’t clear the axles to get thru the opposite end gear. I was able to pound it they with a hammer but removed it as I got frustrated getting the thrust washer lined up on the last inch or so. My question is if this is semi normal (the tight...

Quick fyi. Gear paint is near impossible to find locally. I used some white lithium grease in the package the yellow stuff came in and works great !! Ran out doing so much painting and needed some asap to finish the task Sent from my iPhone using Jeepz.com mobile app

So got the patches looking good. Ready to reassemble !!! Psyched ! Oh and the freeze the pinion and heat the bearing works great vs a press. Hoping my impact gun can deliver the goods for a correct pinion rotational torque. (15 in/lb). Sent from my iPhone using Jeepz.com mobile app

This is what Ive been missing on the two adjustments of ring pinion spacing. Good vid on what the patches really indicate Sent from my iPhone using Jeepz.com mobile app

[emoji106] Sent from my iPhone using Jeepz.com mobile app

I have a lot of tooth contact paint on my diff gears after many attempts at reading contact pattern. Is using brakecleen ok to spray it off while on the case ? Gettiing frustrated at getting a good patch visible. Maybe too thick paint ?? Sent from my iPhone using Jeepz.com mobile app