1995 Viscous coupling.

[dksob81]

Thanks Steve.
This will make it alot easier for people who are needing these instruction, now I won't have to send out 3 emails to hold all the photos.

[FhPt]

Just joined. First post. How do you know when it is time to replace the viscous coupling? I have a 94 JGC and I'm having an issue that feels like driving over a bunch of cattle gaurds that have been spaced out on the highway (rough then smooth then rough then smooth, etc,.). Feels likes something is pulling on the Jeep during rough part. Can't really tell if vibration is from the front or back. It only happens after driving 60 MPH or higher for an hour or more. Letting off the gas makes it worse and constant. Problem still exists when putting Jeep into neutral and coasting. Once the problem starts, it continues even at slower speeds. Pulling over and letting it cool for 15 to 45 minutes allows you to drive another 30 to 60 minutes. History: Transfer case had been rebuilt in 2001 (120K miles on Jeep). CV half shafts and drivers side hub bearings replaced in spring of 2003 (140K miles on Jeep). First noticed problem starting in Fall of 2003. Most of the time didn't have to drive far, so didn't do any work on it. In summer of 2004, problem continuing, changed fluid in transfer case. Changed fluid and filter in transmission. Didn't see any metal shavings. Levels were fine in differentials, but I don't remember if I changed the fluids out. Several months later (Thanksgiving 2004), with 167K on Jeep now, was on a 4 hr trip. Had to pull over after an hour, but after letting it cool on a cold night, for an hour, had same problem after only 5-10 minutes of driving. Problem then rapidly got worse. Pulled over, smelled burnt oil, had smoke coming off of rear differential. Replaced entire rear end (differential, axles, hubs) with a used one that had 68K miles. Problem remained, but was a lot better. However, it is becoming just as bad again after only putting on 500 - 800 miles after replacing the rear end. Replaced fluids in rear and front differentials with synthetic, adding the additive to the rear for the TracLok. No help. Was going to check to make sure the coolent lines to the transmission weren't blocked next. Then was thinking about the front bearings or front differential. Any ideas?

[The_Penguin]

Wow, odd problem. Doesn't sound like the VC. That problem is primarily evident only on tight turns.

[FhPt]

I'll go ahead and start a new thread for this issue then.