Swamp---When I think of heat on a new install, I think pinion bearings and actual tooth scrub as the 2 areas that cause heat the most....carrier bearings are low on the "heat causers".
That said, synthetic will help prevent some of the pinion bearing heat so I think you should start using the Redline 80-140 right now.
Also, the quality of the pattern you developed can influence the heat from the scrubbing/sliding/rubbing that occurs with all Hypoid gears. Synthetic gear oils can reduce this heat also. Too little Backlash is a killer of ring and pinions 'cause no gear oil can make it between the tooth contact and heat shoots way way up. 7~10 thou on backlash is a safe range for the Yota stuff......... Did you ever shoot me a pic of the pattern? And what BL did you measure?

Zuk,
I did send you a pic of the pattern and you said it looked great. I have the backlash set at 9 thou.. I'm gonna order some redline heavyweight shockproof gear oil tomorrow. Hopefully that will do some good. What range should be the total preload on the pinion bearing with everything installed be?

oops. I get so many pics you wouldn't believe it <img src="/forums/images/graemlins/cyclops.gif" alt="" /> It's not something I have recorded lately but I seem to remember PPL plus seal drag plus CBPL was something over 20ish in/lb. I remember looking at yours....I remember thinking that I wished all my patterns would look that good. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Thats what I got...I believe it was around 26in/lb. As far as my pattern goes it must be beginners luck. I came up with that pattern on the second try. Anyhow when I get the synthetic oil I post a followup. Hopefully it will do the trick.

Forgot about this problem for a while b/c I was out of town with work for quite some time. But now that I'm back the problem is still there. I put some of the heavyweight shockproof redline in but it still gets hot as hell after driving a very short distance down the highway. There's about 1000 miles on it now so something aint right. Has anyone ever had one do this before. Zuk is it time to pull it back apart and recheck all the tolerances?

Yep....check the BL first. I don't have any of the old pm's so what ratio and what brand of gear is it? Solid collar or crush?

Zuk...there yukon 4.88's with a solid collar. It's an elocker 3rd not that it makes any difference. I'm in the process of swapping an elocker into my turbo truck...once thats done I'm gonna pull the 3rd from the 4runner and see what the deal is. Hopefully its just the backlash but I know I triple checked it and it was right before I put it in the truck.

wow....this thread almost started a year ago <img src="/forums/images/graemlins/smile.gif" alt="" />

Some heat can be expected......assuming the depth was right then logically that leaves the backlash to think about. If you had unequal tension on the carrier bearings that could cause you grief. That's why I smack the crap out of the bearing caps to allow the carrier bearing races to "self center" (equalize). If this is not done, I suppose the BL could close up some with use.
If you find that the pinion bearings appear to be already worn....or loose....or some heat or blueing action on the races then maybe they somehow ended up to tight or oil is not getting up to the outer pinion bearing for some reason.