Dana 35 rebuild—cause of chipping and wear on spiders and axle gears

MGD_Actual

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Virginal axle mechanic here—Servicing 2006 TJ with dana 35 and, I believe, stock 3.07 gears— fluid with a million sparkly stars of metal flakes and some large enough to pick from the diff bottom.

It appears that the spider gears are worn and chipped—they also have play in them on the little cross shaft. Also the axle gear ends are correspondingly worn. It appears that the pinion and planetary seem to be ok.

Plan is to replace the spider gears and gears on the end of the axle shafts, before it spectacularly hand grenades while cruising a country lane.

Questions:
1. What am I missing.
2. Other than high mileage, what would cause such wear, especially chipping.
3. Are there parts that should be routinely replaced, while in there at this mileage?

Thank you for any guidance.
 
I'd recommend a gear setup kit from Revolution or East Coast Gear.

It comes with all the bearings and seals... except the wheel bearings and seals. You can pocket the shims and ring gear bolts for a next time.

If you're planning on regearing now is the time.

-Mac
 
After my big 'BANG', my pinion was broken in 4 places.
Harmon 4x4 installed an Eaton for me.

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Oh I've had my share of fun. I've had my 35 set up twice by professional shops. Both grenaded. Much rather do it myself.

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-Mac
 
Yeah, this is my second rear end too.
When I bought the Jeep it was in pretty rough shape so I didn't know why it broke the first time, I figured abuse, it's only been 8 years since the first rebuild and I didn't drive it for one and a half years.
Plus I never got a chance to take it off road before it broke the second time so it was nothing but street and this happened. That's pretty sad.
Oh I've had my share of fun. I've had my 35 set up twice by professional shops. Both grenaded. Much rather do it myself.

View attachment 708645View attachment 708646View attachment 708647

-Mac
 
Virginal axle mechanic here—Servicing 2006 TJ with dana 35 and, I believe, stock 3.07 gears— fluid with a million sparkly stars of metal flakes and some large enough to pick from the diff bottom.

It appears that the spider gears are worn and chipped—they also have play in them on the little cross shaft. Also the axle gear ends are correspondingly worn. It appears that the pinion and planetary seem to be ok.

Plan is to replace the spider gears and gears on the end of the axle shafts, before it spectacularly hand grenades while cruising a country lane.

Questions:
1. What am I missing.
2. Other than high mileage, what would cause such wear, especially chipping.
3. Are there parts that should be routinely replaced, while in there at this mileage?

Thank you for any guidance.

You’re not really missing anything, the factory spider/side gears in the Dana 35 are pretty weak. That combined with people not changing the gear oil and/or abusing the axle (off-roading, large tires, some mean combo of all of the above) leads to the pitting.

There are upgraded Spicer spider gears you can get that are net forged, they *should* be better for longevity. I run them in mine, at least for now until I eventually probably get a Super 35 locker.

I’d just get the upgraded spiders (707321x) and fill with new fluid. I run Torco 85W-140 in mine.
 
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