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Old 03-14-2010, 11:03 PM
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Rear differential drama

Howdy...

The rear diff in my 1997 Wrangler Sport has gone to that great muddy trail in the sky. It's stock item... a Dana 35 I believe.

My question is...how difficult is it to repair a rear differential using a kit from 4WD, JC Whitney, etc.? The fact that my old Haynes manual says to take it to the shop gives me cause for concern. On the other hand, it's already broken.

A local shop advised me to buy a complete rear axle from the junkyard, but those cost well over a grand. It seems that repair is worth a shot.

Thanks for your advice.

GW

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Old 03-14-2010, 11:09 PM   #2
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depends on what has failed, just bearings? or ring and pinion?

replacing the bearings isn't too bad, requires some special tools and press work.

the local pick n pulls usually have flat rate pricing, all axles are the same price, around here any axle is between 80 and 160 bux depending on which yard. this is your cheapest option. pop the cover to inspect the condition, and make sure its the right gear ratio.

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Old 03-14-2010, 11:32 PM   #3
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I agree with the shop. D35's are a stout little axle till you hit 34" tires and up. If you want to stay with 35's, get a 44 or Ford 8.8. Sure it's more expensive than fixing the D35, but it's far less likely to bust. 35's IMHO on a D35 is an accident waiting to happen. If you wheel hard, even with a D44 something is going to give. Now I'm not too picky about stuff. I like to get by as cheap as possible, getting only things that are NEEDED. Your axle taking a crap is your Jeep's way of telling you "I need something stronger" I wouldn't doctor up the D35.
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Yeah, I'd stop playing around with that. It looks expensive.
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Old 03-14-2010, 11:38 PM   #4
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i didn't see his tire size posted? either way, the stock axles are rated for up to 32" tires, everyone running 33's on a d35 is beyond its technical limit.

definately upgrade if you wheel and your d35 is broken.
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Old 03-14-2010, 11:43 PM   #5
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You're right, where did I get he's running 35's? it's too late. I need to go to bed. Well then in that case...

What size tire you running man?

I'm off to bed
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Yeah, I'd stop playing around with that. It looks expensive.
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Old 03-15-2010, 12:30 AM
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Rear Differential Drama

I run 31 inch mudders on stock rims. The jeep has 170k miles on it. Having never worked on a rear diff/axle before, I'm not certain if the issue is rings/pinions, etc. The local mechanic didn't specify. If a rebuild kit comes with a good schematic, I'm willing to give it a go. It seems like a great chance to learn.

Thanks.

GW
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Old 03-15-2010, 03:07 PM   #7
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Setting up of the new gears (think it's called backlash) must be done right or it won't take long to wipe them out.
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Old 03-15-2010, 03:25 PM   #8
Knows a couple things...

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Who told you a Dana 35c would cost over a grand? Typically they go for $250-350 which is half the cost it would take to get yours rebuilt. I sold my D35c for $300 or so & it was in superb condition and even had a Detroit Truetrac limited slip differential.

Look around the For Sale areas in the various Jeep forums, used Dana 35c axles are generally pretty easily found for not much $$$.
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Old 03-15-2010, 03:36 PM   #9
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Quote:
Originally Posted by Jerry Bransford View Post
Who told you a Dana 35c would cost over a grand? Typically they go for $250-350 which is half the cost it would take to get yours rebuilt. I sold my D35c for $300 or so & it was in superb condition and even had a Detroit Truetrac limited slip differential.

Look around the For Sale areas in the various Jeep forums, used Dana 35c axles are generally pretty easily found for not much $$$.
for sure.

i have one sitting around you could have for 50 bux. even has brand new synthetic fluid in it worth half the price right there in fluid. lol.
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Old 03-15-2010, 05:15 PM   #10
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I agree, just replace the whole axle, I wanted to regear so I bought a set dana 30 and 35 with 410 gears for $400 bucks and the guy even helped me install them

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