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Old 04-04-2012, 01:19 AM   #1
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HELP! sad day for the jeep.

Okay so I'll tell you what i've got on the jeep and then what happened.

mechanically everything is stock 04' tj sport. I have 31/10.5 tires. seems normal right... i've never had any issues at all mechanically its got about 130,000 km on it 80,000 miles. pretty sure its a DANA 35 but not 100%

I was at a stop sign and gave it some power. nothing more then giving her a little extra to get past a dump truck or something. but it was a more agressive launch in 2 wheel drive. It made an awful clunk and i had assumed it had thrown me out of first gear or something but it was still fully in. the car was nearly unmovable in 2WD but moves in 4WD no problem without a fuss. as we tried to diagnose the problem i drove around a corner and the problem became glaringly apparent and the rear drivers side slammed to the ground and my entire wheel with axle attached rolled up and stopped right beside the drivers door. after the shock kinda went away we examined it and my axel did a full 360 twist and then snapped.

upon further inspection in the shop, it appears that the wear patterns on the inner most bearing is roughly 2-3 times the size as the wear patterns on the intact axle.

I had a mechanic with me in the jeep and he was just as confused as me as to how a piece of hardened steal like that could twist and snap so easily. like i said it was an aggressive acceleration.


Any information would be helpful.

Thank you!

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Old 04-04-2012, 02:36 AM   #2
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Quote:
Originally Posted by Jeep_Heron
Okay so I'll tell you what i've got on the jeep and then what happened.

mechanically everything is stock 04' tj sport. I have 31/10.5 tires. seems normal right... i've never had any issues at all mechanically its got about 130,000 km on it 80,000 miles. pretty sure its a DANA 35 but not 100%

I was at a stop sign and gave it some power. nothing more then giving her a little extra to get past a dump truck or something. but it was a more agressive launch in 2 wheel drive. It made an awful clunk and i had assumed it had thrown me out of first gear or something but it was still fully in. the car was nearly unmovable in 2WD but moves in 4WD no problem without a fuss. as we tried to diagnose the problem i drove around a corner and the problem became glaringly apparent and the rear drivers side slammed to the ground and my entire wheel with axle attached rolled up and stopped right beside the drivers door. after the shock kinda went away we examined it and my axel did a full 360 twist and then snapped.

upon further inspection in the shop, it appears that the wear patterns on the inner most bearing is roughly 2-3 times the size as the wear patterns on the intact axle.

I had a mechanic with me in the jeep and he was just as confused as me as to how a piece of hardened steal like that could twist and snap so easily. like i said it was an aggressive acceleration.

Any information would be helpful.

Thank you!
Sounds like your Dana 35 took a dump on you. Not sure how active you are on this or any other forum but if you are then you know that those Dana 35's don't like any kind of harsh driving. But the reason you could still drive around in 4wd is because everything was fine up front and it was just the front tires pulling you around. If you need to move the Jeep around while your finding another axle or waiting on parts you can just pull the rear driveshaft and leave it in 4wd and let the front tires move you around. And when you get it fixed and you decide to stick with a Dana 35, they're dirt cheap to just buy an entire replacement axle which will be much cheaper than having a mechanic rip your current one apart to replace the broken parts. But while your looking for an axle I'd go ahead and upgrade if you got the extra cash to a Dana 44 or even a ford 8.8. Sorry to hear about the bad luck.

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Old 04-04-2012, 02:56 AM   #3
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thanks! yeah i'd certainly read about the weakness of the d35 but i was shocked when it broke on the road. The trick with throwing it in 4wd seemed to work until the whole axle flew out the side and my jeep scrapped to a halt. it seems the upgrade to a d44 is pretty straight forward and i need this thing fixed ASAP.

And like you said fixing the thing would be hell. we were looking at the damage it caused when it snapped and basically everything on the drivers side is broken in some way.

Also the Diff is in perfect shape other then the bearings and seals and stuff. it was the shaft that ripped in two, and only the drivers side.
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Old 04-04-2012, 07:04 AM   #4
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I don't think an aggressive acceleration alone will do this... it had some 'trauma' some time in it's life. Now maybe a 6000RPM clutch-dump would.....lol!

As far as repair... you can get the 44 ( if you can find one) or go through the housing and inspect EVERYTHING for damage.

IF your shaft snapped:

1. Metal in gear lube
2. Metal in all bearings
3. Metal grinding on/in ring and pinon causing nicks/gouges
4. Possible cracked carrier
5. Most likely thrashed your spider and side gears as well as your clutch paks (if you have a trac-loc) with busted metal getting chewed up in there.

At a minimum... you need all bearings and seals. Don't trust a single one once you introduce metal shavings into the mix.
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Old 04-04-2012, 09:41 AM   #5
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not sure I understand your bearing wear obsevation, but it sounds like it might have a bent housing.
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Old 04-04-2012, 09:49 AM   #6
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Did you get any pictures? I'd like to see exactly where the axle snapped.
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Old 04-04-2012, 03:59 PM   #7
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unfortunately i dont have any good ones. It snapped right after it tapers down but right before the inner bearing. it appears as though it spun around itself once and then snapped just judging by the patterns on it. I dont have the jeep near me at the moment

I assumed the bearings were messed because of the shear volume of metal shavings and chunks of metal in there


Also i looked at the Dana 44 and the gearing on them is usually 4.11 and mine is 3.07 so i'd have to swap out everything wouldn't I? I'd like this to be as quick and painless as possible for now. If i end up taking her apart in a year to upgrade i dont mind.
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Old 04-04-2012, 09:34 PM   #8
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Quote:
Originally Posted by Jeep_Heron
unfortunately i dont have any good ones. It snapped right after it tapers down but right before the inner bearing. it appears as though it spun around itself once and then snapped just judging by the patterns on it. I dont have the jeep near me at the moment

I assumed the bearings were messed because of the shear volume of metal shavings and chunks of metal in there

Also i looked at the Dana 44 and the gearing on them is usually 4.11 and mine is 3.07 so i'd have to swap out everything wouldn't I? I'd like this to be as quick and painless as possible for now. If i end up taking her apart in a year to upgrade i dont mind.
If you wanted to use 4 wheel drive then yeah you'd have to regear them. But if you think you could go that long with no 4 wheel drive then you could just drop your front driveshaft and go on.
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Old 04-04-2012, 09:56 PM   #9
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The same thing happened to the left rear ds on my yj's 35c. The outer bearing was bad and chewed a notch into the shaft. Luckily because it was the outer the axle flopping around ate up the seal and I found gear oil all over my wheel. Replaced the shaft and the bearing/seal, cleaned out the diff and removed the metal shavings from the magnet in the housing and all was good again.
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Old 04-05-2012, 09:46 AM   #10
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Replaced the shaft and the bearing/seal, cleaned out the diff and removed the metal shavings from the magnet in the housing and all was good again.
x2 ^^^^^,if you only broke the axle shaft, this would be the quickest way to get you on the road again.
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Old 04-05-2012, 12:20 PM   #11
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I still think that you could find a used D35 with the same ratio for cheaper than the price of parts and labor if you had a shop do it. Complete ready to bolt in Dana 35's go for about $150-300 around my area. Now if you just need an axle, bearings, and seals and did the work yourself then that might be cheaper. Not to mention that if you know your way around a Jeep then an axle swap is fairly easy if everything is ready to bolt up.
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Old 04-05-2012, 04:35 PM   #12
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I still think that you could find a used D35 with the same ratio for cheaper than the price of parts and labor if you had a shop do it. Complete ready to bolt in Dana 35's go for about $150-300 around my area. Now if you just need an axle, bearings, and seals and did the work yourself then that might be cheaper. Not to mention that if you know your way around a Jeep then an axle swap is fairly easy if everything is ready to bolt up.
You might be right, it's just that I don't usually look at it from a " if you had a shop do it " point of view. I stay away from shops unless I really need one.
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Old 04-05-2012, 04:42 PM   #13
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Originally Posted by 50Johnbob

You might be right, it's just that I don't usually look at it from a " if you had a shop do it " point of view. I stay away from shops unless I really need one.
I'm the same way except when it comes to axles. I'll rip a Jeep apart and put it back together but if I need my axle say regeared or new parts in the diff then I'll pay someone to do it since its all gotta be extremely precise and I don't have all the special tools needed for it. But axle swaps and axle shaft swaps aren't too difficult though. Especially if you read Stu Olsen's write ups on how to do it. I just assumed the OP would have it done at a shop since he said "upon further inspection in the shop" But I'm with ya on staying away from shops. Makes me feel good knowing I did it and if it breaks or messes up I don't have the headache of taking it to the shop who did the work. And it's a helluva lot cheaper too.
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Old 04-06-2012, 02:15 PM   #14
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Hey everyone. Thanks so much for the help!

I couldn't post yesterday because i found a brake to brake dana 35 assembly for 100$, my buddies and I put it in last night and actually found one of my brakes was messed up so we fixed that too.
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Old 04-06-2012, 05:55 PM   #15
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I hope the gear ratio was the same on the one you swapped in?
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Old 04-07-2012, 10:15 AM   #16
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yup. the worst one... 3.07, cant wait to save up enough to get an upgraded front and rear

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