1997 TJ Dana 35 Noise / Thuds

JEEP GC

JEEP GC

Member
Joined
Jun 19, 2021
Messages
54
Location
Charlotte
Background Data:
  1. 255,000 mi. on the TJ
  2. New 4.0 L from S&J
  3. New AX-15 Transmission 5-spd
  4. All engine components NEW (starter, alternator, ect)
  5. 4"lift w/ 33's
  6. New fuzzy dice hanging from the rear view mirror

Original Rear End - Dana 35 w/ 255,000 miles
Son said that in 1st. and 2nd. gear he heard a thud coming from the rear end. Said it sounded like the gears slipping. See picture.

Money is not a concern but I would rather not buy a new rear end. How easy is it to replace entire unit with new parts. I pretty much rebuilt the entire TJ with the help from youz guyz and some YouTube channels. Is there a complete kit to rebuild it? Any help would be greatly appreciated.

20220122_191641.jpg
 
If I'm going to replace spider gears should I replace anything else while I'm there? Is there a complete package I can buy to replace all gears?
 
There are master rebuild kits available, but IF you decide to just replace the spider gears; I would suggest removing the carrier and thoroughly spraying out the inside of the housing and all parts with brake cleaner to remove the metal particulate that is floating around due the damaged spider gears.
Pay special attention to bearing cap orientation to ensure you return them properly.
 
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