So just wanted to close this project out by saying that I finished reinstalling my re-geared Dana 35 today and took it for a short break-in test spin. Total difference in noise and smoothness, I always thought my tires were the source and clearly they weren't! This TJ drives and sounds like a sedan, lol. Quiet under power and also coasting, and it finally revs appropriately (was either under geared or over geared since we bought this 3 years ago). Totally worth the time and money invested in the project.
Just wanted to say thank you again to
@hosejockey61, the videos are an incredible resource. And especially
@Blackjack for always helping me interpret my patterns to make sure I got it right.
Final thoughts for anyone else thinking of doing this:
1. take the axle off the Jeep and work comfortably on it up in jackstands
2. Bought a case spreader, didn't need it
3. Harbor Freight basic shop press got the job done easily
4. Read Billavista's Gear Setup Bible and watch Mike's BFH Garage videos. Even the ones that aren't for your axle, there's knowledge to be learned in all of them.
Thanks again everyone, I appreciate the help along the way
Greg