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Old 03-16-2014, 09:22 AM   #1
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I was offroading yesterday and my dana35's pinion shaft broke in half and cracked the carrier in half and shredded my spider gears. I just had the pinion bearing and carrier bearings replaced about 2 months ago. What would be my best option to fix this? New carrier and spider gears for about 250$? And would i have to reshim it if i were to use a new carrier? I have 4.11 gear ratio and i run 33" tires on my 2.5L 4banger. I was also looking at ten factory super 35 kit with 30 spline shafts and detroit locker.. Let me know what the best option is! Thanks!
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Old 03-16-2014, 11:12 AM   #2
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If your pinion shaft broke then a super 35 kit would do nothing to protect you from that happening again.

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Old 03-16-2014, 01:22 PM   #3
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If your pinion shaft broke then a super 35 kit would do nothing to protect you from that happening again.
Yeah true. So what should i do to rebuild this? Upgrade to a positrac lsd and bolt my ring gear onto that and pop it in the differential and reuse the shims that were on it before??
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Old 03-16-2014, 01:22 PM   #4
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And what would have caused my pinion shaft to break?
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Old 03-16-2014, 01:38 PM   #5
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If you have to replace the carrier anyway might as well go to a 30 spline and maybe add a truetrac. 33s are kinda at the limit for a D35 especially if you pound on it off road.
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Old 03-16-2014, 01:54 PM   #6
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Well i think im going to sell my jeep soon so if i were to get a new open carrier with new spider gears would i have to reshim it when i install the new one?
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Old 03-16-2014, 02:47 PM   #7
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And is it safe to drive my jeep with the rear driveshaft removed with just the side spider gears in there with the c clips on the shafts and no pinion shaft?
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Old 03-16-2014, 11:18 PM   #8
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Dana 35 Jeep Rearend Loaded Differential Carrier Case Spider Gears 3 54 Up | eBay
Omix ADA 16503 48 Differential Carrier Dana 35 with Trac Loc | eBay
New Spicer Dana 35 Carrier Case with Cross Pin Jeep YJ TJ XJ Wrangler I 555 | eBay

so would any of these carriers work in my 97 tj dana 35 with 4.11 gears? So i can just bolt on my ring gear onto the new carrier and slap it in with the original shims?
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Old 03-16-2014, 11:35 PM   #9
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What do you mean by pinion shaft?
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Old 03-16-2014, 11:42 PM   #10
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What do you mean by pinion shaft?
the bar that goes through the spider gears to hold them in place
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Old 03-16-2014, 11:54 PM   #11
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the bar that goes through the spider gears to hold them in place
Ok. Well in that case, a super 35 kit WILL help reduce the chance of that happening again. The super 35 kit will come with a new carrier, usually a Detroit or ARB locker, both very strong units. Good quality super 35 kits will stand up to tough trails on 35's without problems.
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Old 03-17-2014, 12:09 AM   #12
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If you have to replace the carrier anyway might as well go to a 30 spline and maybe add a truetrac. 33s are kinda at the limit for a D35 especially if you pound on it off road.
Unfortunately the D35 Truetrac will only accept a 27 splined shaft...
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Old 03-17-2014, 08:39 AM   #13
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Unfortunately the D35 Truetrac will only accept a 27 splined shaft...
Yeah i may not upgrade shafts. How much stronger would 27 spline chromolys be over stock?
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Old 03-17-2014, 09:05 AM   #14
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Well i think im going to sell my jeep soon so if i were to get a new open carrier with new spider gears would i have to reshim it when i install the new one?
No matter which way you choose to go you will have to do a new set up (shims, bearings etc.)
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Old 03-17-2014, 10:23 AM   #15
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No matter which way you choose to go you will have to do a new set up (shims, bearings etc.)
Is this something i could do with no special tools?
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Old 03-17-2014, 10:28 AM   #16
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Is this something i could do with no special tools?
You will need special tools and the knowledge of how to set up gears. It's not as easy as throwing some shims in and calling it good. It's a very time consuming. You have to get backlash within spec as well as your bearings preload. Again, it's not bolt on and call it good...many very minor adjustments need to be made to get it right.
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Old 03-17-2014, 10:29 AM   #17
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You will need special tools and the knowledge of how to set up gears. It's not as easy as throwing some shims in and calling it good. It's a very time consuming. You have to get backlash within spec as well as your bearings preload. Again, it's not bolt on and call it good...many very minor adjustments need to be made to get it right.
Any idea on how much i would have to pay a shop to install the new carrier and shim it?
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Old 03-17-2014, 10:31 AM   #18
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Any idea on how much i would have to pay a shop to install the new carrier and shim it?
Depends what the going rate is in your area. Usually around a grand.
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Old 03-17-2014, 10:49 AM   #19
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Yeah i may not upgrade shafts. How much stronger would 27 spline chromolys be over stock?
I think literature states a percentage increase of strength of 25%.

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Old 03-17-2014, 10:51 AM   #20
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Depends what the going rate is in your area. Usually around a grand.
Jeez, thats alot... Remember i dont need a new pinion gear or ring gear. The only thing that broke is the carrier and spider gears so its still going to be that expensive?!
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Old 03-17-2014, 11:23 AM   #21
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Jeez, thats alot... Remember i dont need a new pinion gear or ring gear. The only thing that broke is the carrier and spider gears so its still going to be that expensive?!
You can take off some for the cost of the ring and pinion gear then but the setup cost will still probably run you around $700 (guess). Call around and ask and let us know what you find.
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Old 03-17-2014, 11:33 AM   #22
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You can take off some for the cost of the ring and pinion gear then but the setup cost will still probably run you around $700 (guess). Call around and ask and let us know what you find.
I just got the pinion bearing replaced so they wont have to touch that right?
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Old 03-17-2014, 11:48 AM   #23
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1st thing I would do.. is see if there are any used dana 35's in your area that you can just bolt in.. will have to bleed the brakes etc... but that might be the least costly.. try car-parts.com for used axles... or craigslist...

As for repair cost.. call around and shop price... in my area to setup gears its $250 per axle plus parts cost.
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Old 03-17-2014, 01:35 PM   #24
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... How much stronger would 27 spline chromolys be over stock?
Substantially. Good quality hardened alloy 27 spline shafts are essentially as strong as the carbon steel 30 spline shafts that come with the D44.
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Old 03-17-2014, 01:37 PM   #25
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Have you considered upgrading to a Dana 44?

I have been looking at Car-Parts.com My rear is making noise, and I think it will be cheaper to just swap it out than fix it.
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Old 03-17-2014, 02:53 PM   #26
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I just got the pinion bearing replaced so they wont have to touch that right?
The problem is that when an axle goes boom, little fragments can get into a bearing and make short work of them. Bearings are cheap if you look at the big picture.

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1st thing I would do.. is see if there are any used dana 35's in your area that you can just bolt in...
Problem is, he's currently geared at 4:11. Good luck finding an axle with that.

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Have you considered upgrading to a Dana 44?
He stated he was looking to sell his Jeep, so I'm not sure how much he would really want to invest. If I was getting ready to sell, cheap would be what went back under the jeep.
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Old 03-17-2014, 02:56 PM   #27
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Trust me ive looked for dana 44s with 4.11 gears for a long time ive found plenty with 3.73 gears for 400$ but it would have to be regeared and everything else
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Old 03-17-2014, 02:58 PM   #28
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The problem is that when an axle goes boom, little fragments can get into a bearing and make short work of them. Bearings are cheap if you look at the big picture. Problem is, he's currently geared at 4:11. Good luck finding an axle with that. He stated he was looking to sell his Jeep, so I'm not sure how much he would really want to invest. If I was getting ready to sell, cheap would be what went back under the jeep.
And ok so you think i should change all my bearings like my pinion and everything again? This is what my diff fluid looked like bear in my it was changed about 2.5 months ago
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Old 03-17-2014, 03:00 PM   #29
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If you are going to sale your Jeep I'd just look for another axle. All 4 bangers had the 4.11 gears as far as I know. I'm sure you could pick one up for super cheap. I have one with 4.11 gears I took out of my 97 2.5L TJ I'd sale to you but I'm in Utah.
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Old 03-17-2014, 03:27 PM   #30
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And ok so you think i should change all my bearings like my pinion and everything again? This is what my diff fluid looked like bear in my it was changed about 2.5 months ago
I would for piece of mind. The bearing come with the master install kit anyway. MIK run about $120.

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