Novak Conversions Jeep Wrangler TJ engine mounts

Dana 44 with aftermarket cover - fill capacity concerns

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I was a little worried about this. When I pulled the front diff fill plug I could barely get a wrench in there. I ended up buying a special short 3/8" allen socket and using a low profile socket wrench (my backup plan was a stubby allen key, which probably would have worked fine). I couldn't get my torque wench in there (something I didn't mention because I'm still thinking about if/how I should try to get a torque wrench into this tight spot). Somewhere on my to-to list, I plan on looking at this a little closer. If anyone has recommendations on fixes/replacement parts for this I would appreciate it. Otherwise, I will eventually get back around to researching this.

Rockjock/Currie track bar.

https://www.rockjock4x4.com/CE-9120TJS

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I was told from the previous owner that the front and rear axels came off an 04 Wrangler Rubicon (which also has electronic lockers front and rear controlled by two rocker switches).

Not saying you don't have '04 Rubicon axles or that your lockers aren't electric, but the oem ones are pneumatic and operated by turning on electric air pumps.

The factory oil level (based on the oem cover) is to the bottom of the axle shafts.
I use a dipstick to try and match that.
 
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Oh man, was talking about the dirt. Subsection 42rle-fubar would come into play for the switch layout!

It's an old picture, BB is probably dustier now than when the photo was taken!!!!!

Windshield is dirty also, he'd probably bust me for that too. :ROFLMAO: :ROFLMAO: :ROFLMAO:
 
Not saying you don't have '04 Rubicon axles or that your lockers aren't electric, but the oem ones are pneumatic and operated by turning on electric air pumps.

The factory oil level (based on the oem cover) is to the bottom of the axle shafts.
I use a dipstick to try and match that.

@LONGJP2 I'd seen the pneumatic system in another TJ when I was shopping for one. This one has an electrical connection to the diffs that I can hear engage when I flip the rocker switches (I accidently did this last night replacing the stereo head which involved taking the center bezel off that the switches are attached to). II didn't see anything that looked like a pneumatic tank anywhere, but I'll dig into it some more as I have time.

I just finished replacing the geal oil (again), putting in a new stereo (not high priority, but I got a deal on the head I wanted), and replacing the fenders. While replacing the fenders, I removed the fender well guards (plastic inserts) and found that the rear axle breather tube goes into an old plastic soda pop bottle. I have no idea if that is normal either. Looking into that next (might start another thread if I can't find anything). Right now I have this stupid soda pop bottle hanging off the rear end. I'm not sure it's wise to just put it back the way it was. I'm also thinking about not putting the plastic wheel inserts back in (need to see if there's a good reason, otherwise I don't think they add much aesthetically and just make it harder to clean.

Thanks for the info on the axles. That's why I was hoping to positively identify what they are versus take he previous owner's word for it. I've also speculated that the axles did come from an '04 Rubicon at one point, but might not have been stock on that vehicle - so the previous owner would not have been technically wrong, but the info on the axles' origin would be less useful. I'm still learning about this thing! I'm sure some things will always be a mystery.
 
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@LONGJP2 I'd seen the pneumatic system in another TJ when I was shopping for one. This one has an electrical connection to the diffs that I can hear engage when I flip the rocker switches (I accidently did this last night replacing the stereo head which involved taking the center bezel off that the switches are attached to). II didn't see anything that looked like a pneumatic tank anywhere, but I'll dig into it some more as I have time.

The electrical connections you see are just the locker engagement sensors. And there is no air tank. There are two very small air pumps mounted above the transfer case skid that have hoses that run to each diff.
 
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@Rubiconned I have the drain plugs on the differential housing, which I noticed after using the drain plugs on the aftermarket cover. It looks similar to the pic you posted, but not exact. I attached pics of front and rear drain plugs on the housing.

View attachment 565418

View attachment 565419

I'm wondering why Rubiconned's drain plug is between two "ribs" or whatever while Mojowrangler doesn't have the extra rib on either differential.

Now I'm also wondering what is actually engaging and'or unengaging his lockers.

I think pictures of any wiring and/or air lines to both differentials are in order.
 
@Wildman Thanks, that helps. In the "2004 TJ Service Manual.pdf" document, page 25, I see a specification for the "216 RBI (Model 44)" (front and rear) for 1.89 liters (about 2 quarts).

FWIW< I'm not trying to be a jerk but the 216 is the front differential and the 194 is the rear although we're not sure exactly what you have...yet.


EDIT to fix my jerkyness:

216FBI in the front and 216RBI in the rear.
 
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the 216 is the front differential and the 194 is the rear although we're not sure exactly what you have...yet.

@JEEPCJTJ I assumed "Model 44" referred to the Dana 44 axles, which are both listed as "261 RBI (Model 44)" on the page I referenced. "194 RBI" is another rear axle associated with "(Model 35)", which I assume is commonly referred to as the Dana 35.

I just crawled under the Jeep and took a bunch of pics. I'll post them...
 
@JEEPCJTJ Here's a bunch of pics of the front axle...
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My garage is a bit of a disaster because I just finished painting 4 fenders (and three of them are installed - one to go now). I'm also in the middle of a few other projects, all related to this Jeep. The underside is definitely dirty but is was completely caked in mud and oil when I first got it. I didn't even know those diff covers were silver. Everything was black. Before I started working on it, I pressure washed what I could get to the best I could (being mindful to not damage anything). But after crawling under the Jeep and doing a bunch more work, I realize there's a lot more to clean. Eventually I'll start treating parts for rust, painting, etc. but I'm looking at this as a long term project. I'm tying to get some of the "critical" service things done first, along with some "fun" projects (like upgrading the radio to touchscreen/Android-audio and swapping out the fenders today). I also have a pretty long list of stuff to look at again from the PBI at one shop and some recommendations from another shop I had it into for emissions related work.
 
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Novak Conversions Jeep Wrangler TJ engine mounts