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Old 03-08-2014, 11:47 AM   #1
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Hey guys, while I was driving home from school the other day I heard this knocking noise that gets faster as I sped up.

I figured it was the rear axle so I opened it up to find this little bugger (Image attached)

What is that and would that be the cause of the noise? Also, what's that piece that is damaged, and is it possible to just replace that instead of the entire axle or am I looking at a fat bill for a new 8.25?

Thanks in advanced guys. Really appreciate it.
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2000 Jeep Wrangler 2.5L
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-4 33X12.50 Discoverer Cooper S/T
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-Dana 44 Rear Axle With Upgraded 4.88 Gear Ratio
-Rough Country 4 Inch Suspension Lift
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Old 03-08-2014, 02:04 PM   #2
Knows a couple things...

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How did your Jeep get a Chrysler 8.25 in it? You sure that's not a Dana 35 which is what the factory installed?

What is broken is called the case, also known as the carrier which is what holds all the gears. That's not really an expensive or difficult repair, and it certainly doesn't warrant replacing the entire axle.

Does the ring gear (the BIG gear) have any visible damage?

I'd take it to a 4x4/Jeep shop that does a lot of regearing jobs (NOT a general purpose garage or axle shop which will cost more) and have them replace the carrier & whatever gears were damaged. You'll need all new bearings for sure too.

SOMETIMES you can find a good used complete Dana 35 axle that would be an easy bolt-in swap that would cost less than having it repaired. I sold my used/great condition Dana 35 for $350 which is probably 50% of the total bill to repair it.

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Old 03-08-2014, 02:46 PM   #3
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Quote:
Originally Posted by Jerry Bransford View Post
How did your Jeep get a Chrysler 8.25 in it? You sure that's not a Dana 35 which is what the factory installed? What is broken is called the case, also known as the carrier which is what holds all the gears. That's not really an expensive or difficult repair, and it certainly doesn't warrant replacing the entire axle. Does the ring gear (the BIG gear) have any visible damage? I'd take it to a 4x4/Jeep shop that does a lot of regearing jobs (NOT a general purpose garage or axle shop which will cost more) and have them replace the carrier & whatever gears were damaged. You'll need all new bearings for sure too. SOMETIMES you can find a good used complete Dana 35 axle that would be an easy bolt-in swap that would cost less than having it repaired. I sold my used/great condition Dana 35 for $350 which is probably 50% of the total bill to repair it.
Sorry. I was misinformed, I do indeed have a Dana 35.
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2000 Jeep Wrangler 2.5L
-Paramount Offroad Zero Flare Front Fenders
-4 33X12.50 Discoverer Cooper S/T
-Fabtech Front Prerunner Bumper With D Rings
-Dana 44 Rear Axle With Upgraded 4.88 Gear Ratio
-Rough Country 4 Inch Suspension Lift
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Old 04-08-2014, 08:25 AM   #4
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After a month of debating, and a couple of options to consider- i have purchased a Dana 44 which will be arriving in a week or two. Wish me luck guys.
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