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Old 02-10-2013, 05:35 PM   #1
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Maximum Pinion Angle on Dana 35?

I tried searching, but didn't find and answer for this one.

What is the maximum acceptable operating angle for a dana 35? I have a 99 TJ with 4" Tereflex lift (adj upper & lowers), along with an SYE. I just installed a flat skid with a 1" drop. It has a 1" motor mount lift as well.

I'm in the process of tilting the rear end to get the proper alignment of the driveshaft, but it looks like the pinion is going to be at a fairly extreme upward tilt. I'm concerned about proper pinion bearing lubrication, etc. It isn't a daily driver, but I do take it on the highway.

I know I have several other issues to look at (CV joint bind, spring relocation, etc.), but wanted to address this one first, in case that's the limiting factor and I need to drop the t-case a little more.

Thanks,
John

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Old 02-10-2013, 05:39 PM   #2
Knows a couple things...

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Don't worry about lubrication so long as you fill the case properly, worry more about getting the pinion angle set properly. There is no exact pinion angle that is correct for all installations since the correct pinion angle varies by suspension lift height and driveshaft length.

The correct pinion angle is that which matches the driveshaft angle as shown below.
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Old 02-10-2013, 05:43 PM   #3
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No need to worry about lubrication. Gear oil gets slung around in there.:

Rear Clear diff video. - YouTube

Lift your jeep from the bumper or gas tank and put the axle at full droop. Spin the wheels and see if there is any binding. If it spins freely your are good to go assuming you have the correct pinion angle.
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Old 02-10-2013, 06:49 PM   #4
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Biggest concern is binding the double cardan joint at full droop. I have 4" SL , ,MML and standard SYE with UCF high clearance skid and have my pinion direct inline with Lopro mount and bind at full droop ( frame on jackstands and axle drooped. I am going SS SYE and new longer shaft in two months.
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Old 02-10-2013, 08:36 PM   #5
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Quote:
Originally Posted by Jerry Bransford View Post
Don't worry about lubrication so long as you fill the case properly, worry more about getting the pinion angle set properly. There is no exact pinion angle that is correct for all installations since the correct pinion angle varies by suspension lift height and driveshaft length.

The correct pinion angle is that which matches the driveshaft angle as shown below.
I understand how to set the pinion angle, and not asking about what to set it at. My only real concern is any lubrication issues brought on by a pinion angle of 25 degrees or more which may be required to get the proper alignment. I haven't put the digital angle finder on it yet, just guessing it's going to be in that neighborhood.

As far as proper lubrication, I've read about filling on an angle and adding a pint or so extra. I have an aftermarket diff cover (TA Performance Rear Girdle) which already adds ~ 1/2 pint extra capacity, not sure how much more I should add beyond that.
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Old 02-10-2013, 08:43 PM   #6
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Quote:
Originally Posted by TnDz TJ View Post
Biggest concern is binding the double cardan joint at full droop. I have 4" SL , ,MML and standard SYE with UCF high clearance skid and have my pinion direct inline with Lopro mount and bind at full droop ( frame on jackstands and axle drooped. I am going SS SYE and new longer shaft in two months.
Yep,

That's one of the next things to check once I decide whether I can keep the T-case as high as it is now or if I will have to drop it a little more to get an acceptable driveline angle. As it is, I've extended the uppers to their max length and will now have to pull in the lowers (they are slightly more that 1/2 way out) to see if I can get to the desired alignment.

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