On my 2004 CVPI, on the front-end, I just replaced upper and lower ball joints, sway-bar bushings, stabilizer-bar links, brake rotors, and pads. On the rear I replaced the pinion seal, wheel bearings and seals, and gear oil. In between, I replaced the u-joints, and the tail-shaft seal of the transmission.
The test drive seemed fine (no vibrations, odd noises, etc.).
I used the car yesterday. When I got home, and stopped to get the mail from my mailbox, I reached out of the driver’s window, and noticed a lot of heat coming up from the bottom of the car. When I parked, I found that the rear tires were noticeably hotter than the front tires. The wheels were warmer too. They weren’t untouchable — just noticeably warmer than the front. There was a lot of heat coming out from the rear wheel wells. I was really tired, and didn’t think of using the infrared thermometer until things had cooled down a bit. At that time the differential cover was reading about 120 F.
I know that the exhaust pipes run right next to the wheel wells. I tried to convince myself that I was just not used to this car (as it had been in my shop for over a month), but I have a nagging feeling that something that I did is causing too much friction.
When replacing the pinion seal, I made alignment marks, and the nut is exactly where it was prior to removal.
I plan on putting it back on stands this evening. I was going to check the gear-oil level (though it took the correct amount, and I saw no leaks), and I’ll check the ease with which everything is turning. Is there anything else I should be checking?
In the differential, I used Valvoline SynPower 75W140, full-synthetic gear oil. It contains an additive for limited-slip differentials.