Alright, so I changed my front and rear diff covers. (changed oil to synthetic SAE 75W-90)

I assumed from the smell that I had over filled the rear. When I checked the breather, it looked clean as a whistle.

When I crawled under my Jeep, I see oil all over the place. In particular around my passenger side axle and around the end of the axle near the brake.

It seems like oil is coming out everywhere except the brathers. Also, the oil around the brake was really really dark. Not the color of new oil obviously. What gives?

 

Looks like a bad axle seal to me. Might want to get some more opinions, but it looks like you will be replacing those axle seals. Sorry to see thaty man, that sucks.

 

How much oil did you put in?? I hope only the recommend amount. If you overfill it WILL get by the seals. Won't go out the breather unless you get it really hot.

Here's a quick way to check if you overfilled. Take a zip tie and bend it 90 degrees about 4" from the bottom. Dip it in the filler hole up to the bend. Take it out and compare to axle line (see photo). If the oil is above the line in the photo, it's too much oil!! Method works for front or rear diff.

If you measured, it should have been:

FRONT AXLE ± .03 L (1 oz.)
186 FBI (Model 30) 1.0 L (2.1 Pints)
216 RBI (Model 44) 1.3 L (2.7 Pints)

REAR AXLE ± .03 L (1 oz.)
198 RBI (Model 35) 1.83 L (3.8 Pints)
226 RBI (Model 44) 2.25 L (4.75 Pints)

However, aftermarket covers may take a bit more.

 

Very good point, didnt even think of that!!!

 

I'd go with the overfill theory first. I talked with the guys at Desert Rat and they said the axles will spew through the seals sometimes before the oil comes out the breather - especially if you have elevated the breather. I know - they put in my 5.13 gears and overfilled the rear axle. Had a similar leak, though not nearly that bad. I knew about the axle oil level rule before, but just used my pinkie finger as a dipstick. The tech showed me the zip tie trick. He was a bit embarrassed since he (over)filled the axles in the first place!

 

I put about 2.6 quarts in the rear. That sucks.

What should be my course of action at this point?

Thanks for all the replies by the way!

 

Simple. Loosen the diff drain plug (bottom opposite of diff cover) and let a little oil out. Drain the oil until you get the right level per the zip tie dip stick.

Oh, yeah. Don't forget to put something on the ground to catch the oil!

 

I put 2.5 quarts in my rear with my Riddler cover - no seepage, no overflow.

 

woah woah woah... you mean I was supposed to drain my original oil into something?

Cool. I will do that tomorrow. Thanks

 

I assume you have the Dana 44. 4.75 pints = 2.375 quarts. The Riddlers are a bit bigger than the stock, so you are probably on the edge of being good. A tad more, however, might make the difference.