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Old 11-14-2015, 12:11 PM
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Spider gears won't fit!

Have my 98 4.0 in the shop to replace all the rear differential bearings, (D350 and they found that the spider gears need replaced. Ok, no biggie right? Wrong..The shop got a set from Advance (special order); wouldn't fit the carrier. So.... I ordered a set from Morris 4x45 center myself, online (Yukon brand)., gave them to the shop, wouldn't work either.. GRRR. So they ordered a set directly from Dana after giving them all the diff numbers; came in yesterday; wouldn't fit! So now, they have reordered after a lengthy conversation with the Dana person; It will take another 3-5 days for them to get here. Meanwhile, my Jeep has been tied up for 2 weeks. Anyone know what's up with this? Is 1998 that special? Glad I didn't tackle this myself.

Joe

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Old 11-14-2015, 12:17 PM   #2
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With 3 sets of spider gears not fitting, I'm thinking it's not the spider gears. Are you 100% certain you have a Dana 35 and not a Dana 44?

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Old 11-14-2015, 12:21 PM   #3
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sorry, wrong forum. Deleted.
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Old 11-14-2015, 01:02 PM   #4
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Well, there are two different sets for the D35, it depends on the carrier you have. I think the larger is for 3.73+ gears and up. If the sets you have don't fit, you probably need to order them for the smaller carrier for ratios 3.54 and down if I remember correctly.

If you have stock ratios for your 98, 4.0L sport you'd be at 3.07s which is the smaller carrier, meaning smaller gears. In my experience those are also the ones more prone to failure too, but they're not the only weak points of the D35. (shafts, bendy housing..)
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Old 11-14-2015, 01:04 PM   #5
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Originally Posted by Hawk37 View Post
Well, there are two different sets for the D35, it depends on the carrier you have. I think the larger is for 3.73+ gears and up. If the sets you have don't fit, you probably need to order them for the smaller carrier for ratios 3.54 and down if I remember correctly.

If you have stock ratios for your 98, 4.0L sport you'd be at 3.07s which is the smaller carrier, meaning smaller gears. In my experience those are also the ones more prone to failure too, but they're not the only weak points of the D35. (shafts, bendy housing..)
The high and low ratio versions of the carrier use the same spider gears. The only difference between high and low ratio carriers is where the ring gear is positioned on it.
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Old 11-14-2015, 01:15 PM
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Jerry, according to the tag on the diff, and the shape of the pumpkin, it appears to be the D35. It also has the rubber filler plug.

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Old 11-14-2015, 01:17 PM
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Oh, and it is the 3.07 gear ratio. (according to the tag);
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Old 11-14-2015, 01:20 PM   #8
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The rubber fill plug is a good assurance it's a Dana 35.
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Old 11-14-2015, 03:06 PM
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For sure its a D35; just wondering why there are more than one type of spider gears for this axle/ratio.
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Old 11-14-2015, 04:12 PM   #10
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For sure its a D35; just wondering why there are more than one type of spider gears for this axle/ratio.
Installer error?
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Old 11-14-2015, 04:35 PM   #11
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For sure its a D35; just wondering why there are more than one type of spider gears for this axle/ratio.
I figured out the issue... there are two different sets of spider gears depending on if your carrier has the Trac-Lok limited slip differential inside or not.

The carrier on the right has a Trac-Lok, the one on the left is open.
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Old 11-15-2015, 11:56 PM   #12
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The high and low ratio versions of the carrier use the same spider gears. The only difference between high and low ratio carriers is where the ring gear is positioned on it.
Huh, thanks for correcting me Jerry. I'd made that assumption because I had a '89 YJ project I bought with busted spider gears in it. The smallest 2 spider gears in the 4.10 '93 D35 I replaced it with were larger than the ones I pieced together from the '89.

Doing some research, it looks like that mush have been the differences between the non ABS and ABS version of the carrier not the split, like I'd thought.

Dana only lists 2 PN's for the 97-2000 TJ Dana 35C:
707321X - Standard Inner Parts Kit
708184 - Trac lok
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Old 11-16-2015, 12:05 AM   #13
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The carrier doesn't know or care if the Jeep has ABS or not.
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Old 11-16-2015, 02:20 PM   #14
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The carrier doesn't know or care if the Jeep has ABS or not.
I don't see any reason as to why, but everything I've been finding says the D35C carrier was redesigned in the early 90's for ABS. After the update the newer "ABS Carrier" was used in ABS and non-ABS models from then on.

From Spicer's Catalog it looks like they used the earlier carrier with ABS on one or two models, but switched when ABS became more prevalent in late '93.

The two carriers can be interchanged as complete units, but their internals cannot be. The hub of the spider gears are different. The ABS version is the newer 1.56" diameter the older Non-ABS version is 1.62."

OP, its possible a previously owner blew the spider gears and grabbed an older D35C carrier out of the junk yard to fix it. In which case you would need the older spider set.

The older inner kits are PN: 707247X from spicer.

Its a long shot, but hope that helps.
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Old 11-16-2015, 06:31 PM
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Thank you for that information; going to talk to the mechanic tomorrow to see if we can get this straightened out.

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Old 11-17-2015, 12:46 PM   #16
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All of the '97 and newer Dana 30 and Dana 35 axles installed onto the TJs shipped "ABS ready" from the factory, right down to axle shafts coming with the ABS tone wheels installed and housings drilled for the ABS sensor mounting brackets. That was whether or not the TJ actually had the optional extra cost ABS option installed or not.

So you should not find a different carrier whether your Jeep actually came with a working ABS system or not. The only difference in your spider gears should be as was described in post #11 where I gave you the two different part numbers for the spider gears for both Trac-Lok and non-Trac-Lok version axles. That information comes directly from the 1998 Mopar parts manual which only lists two spider gear part numbers... one for Trac-Lok and one for non-Trac-Lok. You can confirm that by taking a closer look at the image I included in post #11 above, click on it to make it bigger if you can't read it. No mention is made of any difference for ABS or not.
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Old 11-17-2015, 01:33 PM   #17
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P.S. the 'DSA' code given next to the spider gear part numbers decodes to the 'Anti-Spin' axle option which is code-speak for the Trac-Lok limited slip differential.
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Old 11-18-2015, 10:19 AM   #18
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All of the '97 and newer Dana 30 and Dana 35 axles installed onto the TJs shipped "ABS ready" from the factory, right down to axle shafts coming with the ABS tone wheels installed and housings drilled for the ABS sensor mounting brackets. That was whether or not the TJ actually had the optional extra cost ABS option installed or not.

So you should not find a different carrier whether your Jeep actually came with a working ABS system or not. The only difference in your spider gears should be as was described in post #11 where I gave you the two different part numbers for the spider gears for both Trac-Lok and non-Trac-Lok version axles. That information comes directly from the 1998 Mopar parts manual which only lists two spider gear part numbers... one for Trac-Lok and one for non-Trac-Lok. You can confirm that by taking a closer look at the image I included in post #11 above, click on it to make it bigger if you can't read it. No mention is made of any difference for ABS or not.
I agree a '98 should have a Trac-Lok or the 1.56" spider gear hub carrier used from '93 on. The two can be identified based on the solid info you provided in post #11.

I also agree that ABS is not really the determining factor between the older and newer carriers, and shouldn't be a factor for the OP. It seems they updated the carrier design in mid '93. I'm simply suggesting that there is the possibility an older carrier made its way into the OP's D35, perhaps from a previous repair.

ECGS has a good picture of the 1.56" measurement for reference:
(The older carrier spider gears would measure 1.62" at the same point)



In either case the carrier bore will be slightly larger than the spider gear hub to allow the spider gear to slip in.

OP, if you find you don't have a Trac-Lok, and the 707321X kit doesn't fit, I'd recommend you (or the mechanic) measure the bore to see if its closer to 1.56" or 1.62."
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Old 11-19-2015, 07:55 AM
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Thanks for all that good information; the mechanic had a discussion with the Dana people, and re-ordered a new set of gears, which should arrive today; maybe these will fit, keeping my fingers crossed.

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