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kokanee13 02-09-2011 03:39 PM

2003 overlander rear diff questions/help
My old mans got an 2003 overlander. The rear diff is leaking where the driveshaft goes into the diff. Whats wrong with it? Can it be driven? How hard is it to fix? And where the hell is the drain plug on that diff? He's leaking about 5 tables spoons a night from there.

kokanee13 02-09-2011 03:48 PM

Re: 2003 overlander rear diff questions/help

SvenskaJeepGuy 02-09-2011 04:25 PM

Re: 2003 overlander rear diff questions/help
03 wj overland advice can be found here......

LTrainGC 02-09-2011 04:28 PM

Re: 2003 overlander rear diff questions/help
Also see:

2005JGC 02-10-2011 02:21 AM

Re: 2003 overlander rear diff questions/help
5 table spoons a night means someone WAY overfilled it, or the seal is completely toast and he parks it face down on a 50 degree hill.

That is the pinion seal, alot of people do it differently and MANY do it wrong, really to do them your supposed to jack up the rear of the vehicle, remove the rear wheels, calipers and rotors... disconnect the driveshaft, then measure turning torque of the differential (a dial torque wrench on the pinion nut). from there you rip off the pinion nut use a puller on the companion flange and pull the seal, replace with new (I like to use anaerobic sealant on the outter sealing surface and lube up the inner seal surface with white lithium grease (if it didnt come prelubed). install new pinion nut and torque until it snugs up then a little more, measure turning torque and tighten pinion nut until it is back to what it was.

ALOT of people either mark the pinion nut to pinion gear orientation and just tighten the pinion nut until the marks line back up OR just rip it on by feel with an impact (yikes). the first WAY overtightens it, the later... yikes.

Its a decently large job BUT unfourtunatly its a job you dont know if its done properly unless you do it yourself.

btw there is no drain, you pull the entire cover, the cover and diff housing need to be cleaned, new rtv used and bolted back together after a good cleaning. On the overland you need some Mopar LSD additive or the clutchpacks will bind and chatter.

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