Hi Michael,
Clearly as you say, there's no way to fill the housing while the
shift cover is off. There is no seal next to the differential housing
like the driver's side axle, the only seal is after the box as you may
see: http://www.rightcoastcrawler.com/bil.../insideD30.htm
So I would tilt the axle in that direction and over fill the
differential fill plug, by that five ounces.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

Michael Vincenty wrote:
>
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the axle
> shift motor housing when it is on the side of the axle (not on top). What I
> am saying here, is that if you try and add the oil before the housing cover
> is installed, it will all spill out. What gives? Also, I noticed that when
> I had the axle shift motor cover off, that oil would spill into the housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv

 

Hi Michael,
Clearly as you say, there's no way to fill the housing while the
shift cover is off. There is no seal next to the differential housing
like the driver's side axle, the only seal is after the box as you may
see: http://www.rightcoastcrawler.com/bil.../insideD30.htm
So I would tilt the axle in that direction and over fill the
differential fill plug, by that five ounces.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

Michael Vincenty wrote:
>
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the axle
> shift motor housing when it is on the side of the axle (not on top). What I
> am saying here, is that if you try and add the oil before the housing cover
> is installed, it will all spill out. What gives? Also, I noticed that when
> I had the axle shift motor cover off, that oil would spill into the housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv

 

Hi Michael,
Clearly as you say, there's no way to fill the housing while the
shift cover is off. There is no seal next to the differential housing
like the driver's side axle, the only seal is after the box as you may
see: http://www.rightcoastcrawler.com/bil.../insideD30.htm
So I would tilt the axle in that direction and over fill the
differential fill plug, by that five ounces.
God Bless America, ßill O|||||||O
mailto:-------------------- http://www.----------.com/

Michael Vincenty wrote:
>
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the axle
> shift motor housing when it is on the side of the axle (not on top). What I
> am saying here, is that if you try and add the oil before the housing cover
> is installed, it will all spill out. What gives? Also, I noticed that when
> I had the axle shift motor cover off, that oil would spill into the housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv

 

To fill the shift housing after removing the cover / fork assy you remove
the shift indicator light switch and pour the gear oil in through the hole.

The right (passenger) side of the XJ/YJ disconnect D30 does not have a
conventional inner carrier seal, it seals at the outer axle shaft. All the 5
ounces of oil does is "prime" the disconnect assembly until it gets lube
from the differential fill. It is, however, very important to fill this area
when reassembling. I've seen several of these sieze up after repairs,
probably because the diff was low on oil to begin with and the owner failed
to top it up.

"Michael Vincenty" <mvincenty@core4x4.org> wrote in message
news:Bt2dnTAdda4gPJjcRVn-og@adelphia.com...
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when
you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the
axle
> shift motor housing when it is on the side of the axle (not on top). What
I
> am saying here, is that if you try and add the oil before the housing
cover
> is installed, it will all spill out. What gives? Also, I noticed that
when
> I had the axle shift motor cover off, that oil would spill into the
housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv
>
>
>

 

To fill the shift housing after removing the cover / fork assy you remove
the shift indicator light switch and pour the gear oil in through the hole.

The right (passenger) side of the XJ/YJ disconnect D30 does not have a
conventional inner carrier seal, it seals at the outer axle shaft. All the 5
ounces of oil does is "prime" the disconnect assembly until it gets lube
from the differential fill. It is, however, very important to fill this area
when reassembling. I've seen several of these sieze up after repairs,
probably because the diff was low on oil to begin with and the owner failed
to top it up.

"Michael Vincenty" <mvincenty@core4x4.org> wrote in message
news:Bt2dnTAdda4gPJjcRVn-og@adelphia.com...
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when
you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the
axle
> shift motor housing when it is on the side of the axle (not on top). What
I
> am saying here, is that if you try and add the oil before the housing
cover
> is installed, it will all spill out. What gives? Also, I noticed that
when
> I had the axle shift motor cover off, that oil would spill into the
housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv
>
>
>

 

To fill the shift housing after removing the cover / fork assy you remove
the shift indicator light switch and pour the gear oil in through the hole.

The right (passenger) side of the XJ/YJ disconnect D30 does not have a
conventional inner carrier seal, it seals at the outer axle shaft. All the 5
ounces of oil does is "prime" the disconnect assembly until it gets lube
from the differential fill. It is, however, very important to fill this area
when reassembling. I've seen several of these sieze up after repairs,
probably because the diff was low on oil to begin with and the owner failed
to top it up.

"Michael Vincenty" <mvincenty@core4x4.org> wrote in message
news:Bt2dnTAdda4gPJjcRVn-og@adelphia.com...
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when
you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the
axle
> shift motor housing when it is on the side of the axle (not on top). What
I
> am saying here, is that if you try and add the oil before the housing
cover
> is installed, it will all spill out. What gives? Also, I noticed that
when
> I had the axle shift motor cover off, that oil would spill into the
housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv
>
>
>

 

To fill the shift housing after removing the cover / fork assy you remove
the shift indicator light switch and pour the gear oil in through the hole.

The right (passenger) side of the XJ/YJ disconnect D30 does not have a
conventional inner carrier seal, it seals at the outer axle shaft. All the 5
ounces of oil does is "prime" the disconnect assembly until it gets lube
from the differential fill. It is, however, very important to fill this area
when reassembling. I've seen several of these sieze up after repairs,
probably because the diff was low on oil to begin with and the owner failed
to top it up.

"Michael Vincenty" <mvincenty@core4x4.org> wrote in message
news:Bt2dnTAdda4gPJjcRVn-og@adelphia.com...
> Ok,
>
> The factory service manual for my 90 YJ clearly says page 2-59 that when
you
> install the axle shift motor housing for an MJ/XJ and YJ, step # 1 is:
>
> Add 148 ml (5 ounces) of of SAE 75W-90, API grade GL 5 hypoid gear oil
> lubricant to the axle through the shft motor housing opening.
>
> My question is how does one go about adding 5 ounces of gear oil to the
axle
> shift motor housing when it is on the side of the axle (not on top). What
I
> am saying here, is that if you try and add the oil before the housing
cover
> is installed, it will all spill out. What gives? Also, I noticed that
when
> I had the axle shift motor cover off, that oil would spill into the
housing
> area from the differential pumpkin. Is is normal, given that there is an
> inner axle seal inside the pumpkin? Given that gear oil flows from the
> pumpkin to the axle shift motor cover, does this indicate that the factory
> service manual is wrong?
>
> Anybody have thoughts on this?
>
> Thanks
>
> mpv
>
>
>