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Old 06-03-2013, 03:40 PM   #1
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Dana 35 Rebuild

Does anyone know how to rebuild a Dana 35 ring and pinion. or have any sites that I can research to find out. I have been looking online and can't find anything. Usually I would just take it apart and figure it out and most of the mechanic work I have been able to do that. But with these gear it seems there may need to be a bit more precision when rebuilding that.
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Old 06-03-2013, 04:55 PM   #2
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DANA 35 Rebuild

I am doing this in my spare time now with an extra DANA35 that I have.

First question is why are you doing this is to regear to a higher gear because of larger tires?

Or did you blow the rear end on the trail?

Bottom line is you need a special tool called a differential case expander it is about a 350 dollar tool plust a shim kit and the new ring and pinion once you add it all up most people can find a complete rear end for less somewhere else or they upgrade to a DANA 44 in the rear which is a better and stronger rear end for off road?

if you are looking to save some money better off searching craigslist for someone who is doing an upgrade to a DANA 44 and wants to sell there Dana35 to recoup some of the cost of the upgrade.

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Old 06-03-2013, 05:35 PM   #3
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You don't really need a case expander for gear changes, it just might make it a little easier. And if you have never done a Regear or installed gears before, I wouldn't suggest it. You need to be able to set the backlash of the pinion gear and ring gear, a process that can take hours and lots of taking the differential out and adjusting shims. To set the backlash, you will need a dial indicator with magnetic base and lots of patience. Its definitely doable for a first timer but you just need to move slow and check your work. We are talking about thousandths of an inch adjustments. If you will be changing bearings too, you will need a press to put them on and a bearing puller to get them off. There are some great writeups to follow along if you do it yourself. Let me know if you need any Dana 35 parts, I just took mine out to swap in a Dana 44
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Old 06-03-2013, 09:22 PM   #4
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I am doing it because mine blew, and I wasn't even off roading, and I can't afford to take it and have it done. I would rather buy a complete axel but, I can't find one at a decent price.

If I go ahead and upgrade to Dana 44 would I need to upgrade the front also? it is still the factory dana 30.
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Old 06-03-2013, 09:26 PM   #5
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Quote:
Originally Posted by phortie
I am doing it because mine blew, and I wasn't even off roading, and I can't afford to take it and have it done. I would rather buy a complete axel but, I can't find one at a decent price.

If I go ahead and upgrade to Dana 44 would I need to upgrade the front also? it is still the factory dana 30.
No.
You do not have to upgrade the front axle.
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Old 06-03-2013, 10:30 PM   #6
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Quote:
Originally Posted by phortie View Post
I am doing it because mine blew, and I wasn't even off roading, and I can't afford to take it and have it done. I would rather buy a complete axel but, I can't find one at a decent price.

If I go ahead and upgrade to Dana 44 would I need to upgrade the front also? it is still the factory dana 30.
PM me where are you located, I will have a complete axle with 3.73 gearing and a truetrac with 65000 miles on it it works fine I am upgrading mine to a dana 44 with a locker and 4.88's it was just too much of an upgrade for the 35
Rob
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Old 06-03-2013, 11:34 PM   #7
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will a Dana 35 from a Cherokee fit a wrangler?
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Old 06-03-2013, 11:42 PM   #8
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Originally Posted by phortie View Post
will a Dana 35 from a Cherokee fit a wrangler?
Eventually...

Cherokees have leaf springs. To retrofit a Cherokee D35 to a TJ would be a huge waste of time
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Old 06-04-2013, 12:00 AM   #9
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lame. I really need a new axle. rebuilding one seems dang near impossible.
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Old 06-04-2013, 12:19 AM   #10
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Where in co are you? I just checked classifieds in utah and there's a bunch of 35's around here for dirt cheap.
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Old 06-04-2013, 12:21 AM   #11
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Also if you ask around enough I'm SURE you know someone who knows how to do it and will do it for you cheap. I just moved here and I've already found someone willing to do my axles for a 30 rack of natty. It just doesn't get any cheaper.
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Old 06-04-2013, 02:40 AM   #12
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As long as its the same gearing and from a TJ, a dana 44 will fit. Know that the dana 44 pinion yokes are longer than the dana 35 ones(about an inch), so if you have a stock driveshaft and under a 3" lift or so you may need to have it shortened. It seems over 3" on a stock driveshaft works for most people. Keep looking, I found a dana 44 for under $400, put around $75 into restoring it, and put it in myself. Saved a ton. If you need the jeep to drive around just fix it as cheap as possible and drive it gently until you can upgrade
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Old 06-04-2013, 07:17 AM   #13
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or, if you can find an explorer with an 8.8 rear end take that. it'll be about as much work as a Cherokee rear end but be much heavier duty. doing this will allow you to upgrade more later. its problem going to cost as much by the time your done as getting a plug and play axle would, but you could also get disc breaks at the same time.
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Old 06-04-2013, 09:57 AM   #14
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I'm in Colorado Springs
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Old 06-04-2013, 11:25 AM   #15
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right now my ratio is a 3.07. if I buy an axle with a different ratio would that be ok?
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Old 06-04-2013, 11:32 AM   #16
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Quote:
Originally Posted by phortie View Post
right now my ratio is a 3.07. if I buy an axle with a different ratio would that be ok?
If you don't want to use 4wd
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Old 06-04-2013, 11:55 AM   #17
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so if I swapped my rear axle with an axle with a different ratio, that would cause 4x4 not to work? sorry, this is the first I have ever dealt with this, so I have no idea.
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Old 06-04-2013, 11:59 AM   #18
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Quote:
Originally Posted by phortie View Post
so if I swapped my rear axle with an axle with a different ratio, that would cause 4x4 not to work? sorry, this is the first I have ever dealt with this, so I have no idea.
You're 4x4 will still "work" but you won't be able to use it and you won't go far because your driveshafts and axles will try to turn at different rates because of the different ratios in the front and rear diffs. And one of those components or your t-case will catastrophically fail if you use 4x4 with a setup like that. Make sense?
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Old 06-04-2013, 12:09 PM   #19
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yes, makes perfect sense.

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