Novak Conversions Jeep Wrangler TJ radiator
Wow, it is like reading an unfinished novel.

This is looking odd.

View attachment 298594

It looks like chunks in the tube and shavings around the race when you zoom in.
Yeah, that’s rust from the upper part of the axle tube right behind where the exhaust dumps. That area gets hot and cool and has rusted due to the stupid exhaust. Chunks of rust fell into the tub and spoiled the gear lube in the shaft. The gear oil was replaced about 2 weeks ago and the tube was cleaned about 1 week ago. The bearing on the shaft was actually still good, but it’s a situation that needs to be corrected.
 
Jeeps are parked for winter. Truck has heated seats, steering wheel and electric heat until up to temp. Plus I wear a Milwaukee jacket. That’s my solution.
I’ve been to MN. I go there once a year. I totally know why you park the Jeep for winter. The salt there must be terrible because the cars there are all rotted out. It’s unreal to see. 😞
 
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I hate electrical. I hope this is easy enough, but I gotta find a fuse to tap into that’s only when I turn the key on, and my instructions said “ground the brown wire” and I can’t find a brown wire. 😂 I also am wondering if I should put them under the seat covers or go under the actual stock fabric. I will need a few days to do this at the same time I do some sound deadening and BedRug. It will change the inside of the Jeep for sure.

Ultimately, I think my wife got the seat heaters for her. She’s a seat heater junkie. 😂
Yeah, auto electrical work isn’t my favorite either. I used those tap-a-circuit things in the fuse box behind the glove box;
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I’m sure your 05‘s fuse box is different than in my 97, though. The fuses provided with my seat heater are 7.5 amp for each so a switched 15 amp circuit should cover two seats. I used the 20 amp circuit for the rear wiper (which I don’t have since no hard top). Here’s the wiring diagram with mine:
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The switches worked well in the center console (for ease of wiring and use):
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One of these stepped drill bits is perfect for making holes in the plastic:
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Yeah, auto electrical work isn’t my favorite either. I used those tap-a-circuit things in the fuse box behind the glove box;
View attachment 298603
I’m sure your 05‘s fuse box is different than in my 97, though. The fuses provided with my seat heater are 7.5 amp for each so a switched 15 amp circuit should cover two seats. I used the 20 amp circuit for the rear wiper (which I don’t have since no hard top). Here’s the wiring diagram with mine:
View attachment 298605
The switches worked well in the center console (for ease of wiring and use):
View attachment 298606
One of these stepped drill bits is perfect for making holes in the plastic:View attachment 298607
Very clean and very helpful! I have a hardtop and all the parts for the rear wiper, but I’ve never put all the parts together. I’m familiar with that fuse board behind the glove box. I will look over my diagram and see what I can tap into because I really like how clean the tap a circuit solution is. I also have a stepped drill bit, so I can do that for the two switches. Very helpful wiring diagram too. Thank you so much for taking the time to post all this. Merry Christmas. It’s still the 25th here!
 
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DMAN now you're making me think about putting seat heaters in my Jeep.....

I have the heated and cooled seat & heated steering wheel in my truck and REALLY like the heated steering wheel. I also have a heated seat on my Harley and I do know how much of a difference it can make on a cold morning or day.
 
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DMAN now you're making me think about putting seat heaters in my Jeep.....

I have the heated and cooled seat & heated steering wheel in my truck and REALLY like the heated steering wheel. I also have a heated seat on my Harley and I do know how much of a difference it can make on a cold morning or day.
Ooh… heated steering wheel! My wife’s SUV has that and if I could figure out a clean way of doing it in anything I drive, I would 😎
 
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DMAN now you're making me think about putting seat heaters in my Jeep.....

I have the heated and cooled seat & heated steering wheel in my truck and REALLY like the heated steering wheel. I also have a heated seat on my Harley and I do know how much of a difference it can make on a cold morning or day.
Heated seats in the jeep makes snow runs way more fun.

My Ram has all the goodies as well. The best is when I have the seat cooler on and the wife is running the heated seats lol.

What I really need to do is put some warm gloves under my seat. I always remember to layer up but someone never remember gloves. Now excuse me while I go shop on Amazon.
 
Heated seats in the jeep makes snow runs way more fun.

My Ram has all the goodies as well. The best is when I have the seat cooler on and the wife is running the heated seats lol.

What I really need to do is put some warm gloves under my seat. I always remember to layer up but someone never remember gloves. Now excuse me while I go shop on Amazon.
Gloves are on my list too. No one bought me any. The Viair 400P is also on the short term list.
 
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Heated seats in the jeep makes snow runs way more fun.

My Ram has all the goodies as well. The best is when I have the seat cooler on and the wife is running the heated seats lol.

What I really need to do is put some warm gloves under my seat. I always remember to layer up but someone never remember gloves. Now excuse me while I go shop on Amazon.

Must not be gripping that steering wheel tight enough. I have a hard time trying to drive with gloves on.

I've got heated grips on my Harley too so I'm spoiled. And I LOVE the heated steering wheel. I'd love that option in the TJ. One of the reasons I'd never done the buggy thing was because I had got to the point where if my leg got cold I was done for days. So having the heat in the Jeep with the doors on was enough to keep me warm.

Same thing happens in my truck but it's my daughter turning the heat on while I got the A/C blasting and the cooled seats running.

Gloves are on my list too. No one bought me any. The Viair 400P is also on the short term list.

Dang Nab you got a list. Better get shopping. I take a XXL in gloves... ;)
 
Wow, it is like reading an unfinished novel.

This is looking odd.

View attachment 298594

It looks like chunks in the tube and shavings around the race when you zoom in.
ya i missed this ............1 is prefect shiny and clean........ and this 1 is contaminated. not all rusty either, some of that is shiny new shards.

so SYE, driveshaft, pinion all verified ..................what if that carrier bearing is whacked and under load it's givin to some shear and that's our bitch? is this possible?
 
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ya i missed this ............1 is prefect shiny and clean........ and this 1 is contaminated. not all rusty either, some of that is shiny new shards.

so SYE, driveshaft, pinion all verified ..................what if that carrier bearing is whacked and under load it's givin to some shear and that's our bitch? is this possible?
I can check that bearing out.
 
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I can check that bearing out.
again just a guess but could coincide with the rotational noise. as the pinion comes around under load it's pushin the ring and the carrier bearing gives it pushes offline, when the pinion tooth clears the stress relieves and you get that cluck when it comes back in.

IDK does it make sense to anyone else?
 
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Do you have a magnet in your diff?
Are you talking about the magnet that is sometimes on the back of the fill hole plug? I don't think it is magnetic. I did drain the fluid about 2 weeks ago. It was clean. There was nothing on the fill hole plug.

Revolution 4.56 Master Gear Set + Eaton E-Locker.
 
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again just a guess but could coincide with the rotational noise. as the pinion comes around under load it's pushin the ring and the carrier bearing gives it pushes offline, when the pinion tooth clears the stress relieves and you get that cluck when it comes back in.

IDK does it make sense to anyone else?
At church today I talked with a flight mechanic. He also dabbles in cars, but he's young. I mentioned my jeep has a problem somewhere in the diff. He said he had a problem one time. I said it sounds like glub, glub, glub and increases with road speed. He said he had that problem one time in his Toyota and if he recalled correctly it was the carrier bearing. I said, really? It sounded like this, and he said, yeah, and it got faster until it was just one sound.

So, there may be something to this.
 
At church today I talked with a flight mechanic. He also dabbles in cars, but he's young. I mentioned my jeep has a problem somewhere in the diff. He said he had a problem one time. I said it sounds like glub, glub, glub and increases with road speed. He said he had that problem one time in his Toyota and if he recalled correctly it was the carrier bearing. I said, really? It sounded like this, and he said, yeah, and it got faster until it was just one sound.

So, there may be something to this.
it sucks nobody wants to chase a problem that deep but since other players have been cleared and the only witness of anything is the tainted tube fluid, it has to be investigated b4 you don't have any more hair to pull.

as far as the diff lookin clean those particles are minute, and the bearing rotation could flow oil into the tube where the particles settle and they have not made it back into the diff yet.
 
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I gotta go to the store to get a tap to help my kid fix something on his new (refurbished) MTB, so if I’m up for it later I’ll remove the carrier and look at and rotate that bearing. We’ll be tapping the Fox shock for a larger bolt bc PO stripped it. 🙄

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I got into the differential. I took some pics of everything and you can see them down below. Also, take careful note of the shards are found in the differential. These were mostly on the driver side where the carrier bearing was. I can’t find anything wrong with the carrier bearings or the ring or pinion teeth. There’s a slight rough spot on top of one of the pinion teeth. I’ve taken a picture of it. I can feel it when I rub my nail across it. The pinion bearing seems super tight. So, I still don’t know what’s going on if anything back here. Hoping some of your good eyes can see something.

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Novak Conversions Jeep Wrangler TJ radiator