2000 TJ rear differential rebuild

I agree. Remove 1-2 thou. Since they don't put 1 or 2 thou shims in any of the kits, you'll need to do some math with the shims you have to get there. Confirming this is for your Dana 35?
 
Can you take out .001-2?

Yeah I can do that. Is pinion depth too deep now then? Not really sure what I am looking for on the pattern? It looked pretty centered to me. I really appreciate the guidance here. Its getting close to finishing this up... then I have to do the front :)
Thanks
Dave.
 
I agree. Remove 1-2 thou. Since they don't put 1 or 2 thou shims in any of the kits, you'll need to do some math with the shims you have to get there. Confirming this is for your Dana 35?

I bought an extra shim kit so I can drop it 1 or 2 thou no problem. What am I looking for on the pattern?
Yes it is a Dana 35.
 
I bought an extra shim kit so I can drop it 1 or 2 thou no problem. What am I looking for on the pattern?
Yes it is a Dana 35.

In your pics from earlier the contact seemed heaviest toward the tip of the drive side. In the latest it looks much better but possibly biased towards the root.pic is somewhat blurry.

Not as important is the pics of the coast side. It tells the same thing but more exaggerated.
 
In your pics from earlier the contact seemed heaviest toward the tip of the drive side. In the latest it looks much better but possibly biased towards the root.pic is somewhat blurry.

Not as important is the pics of the coast side. It tells the same thing but more exaggerated.

OK thanks again. I marked the root with a tooth pick and tried to get better pictures. Let me know what you think. Still too deep?

IMG_2814.jpg
 
Did you change anything or just take a different picture? You're still too deep....maybe the 1-2 thou as mentioned before. Less paint will help too. A lot of people will misinterpret a pattern as being deep due to a straight line at the root when it is actually too much paint piling up.

Take a look at this video for basic pattern reading...

 
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Did you change anything or just take a different picture? You're still too deep....maybe the 1-2 thou as mentioned before. Less paint will help too. A lot of people will misinterpret a pattern as being deep due to a straight line at the root when it is actually too much paint piling up.

Take a look at this video for basic pattern reading...


Thats a great video...!! I've watched a lot of the BFH videos and just realized that's your profile picture! Sorry about that. :)

I hadn't changed anything in that last picture. I just tried to get a better view of it but now see that the harsh line at the bottom near the root is showing its too deep. I'll just go and make a change and see how it goes! Thanks again.
Dave.
 
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Thats a great video...!! I've watched a lot of the BFH videos and just realized that's your profile picture! Sorry about that. :)

I hadn't changed anything in that last picture. I just tried to get a better view of it but now see that the harsh line at the bottom near the root is showing its too deep. I'll just go and make a change and see how it goes! Thanks again.
Dave.

Ok... I now officially feel like I'm chasing my tail.. :) I took 4 thou out of the pinion before it made much difference. Backlash is at 7 thou with 20inc lbs of preload. Now I seem to be running off the end of the tooth on the coast side... Suggestions? HAHA

IMG_2816 (1).jpg


IMG_2817.jpg
 
Do what we suggested and only remove 2 thou. Run the pattern and show us. You may not see the difference but my guess is that it's closer than you think.
 
I think you're there, but do me a favor to confirm. Get all the paint off that ring gear including the adjoining teeth to the main pattern. Then apply as little as you can to only three teeth, in three different spots and then re run the pattern. I know this seems like a lot of extra work but I really want to see a more defined pattern and I think excess paint is skewing it some. When you run it, it will also leave a ghost pattern on the other teeth that will provide info as well.
 
I think you're there, but do me a favor to confirm. Get all the paint off that ring gear including the adjoining teeth to the main pattern. Then apply as little as you can to only three teeth, in three different spots and then re run the pattern. I know this seems like a lot of extra work but I really want to see a more defined pattern and I think excess paint is skewing it some. When you run it, it will also leave a ghost pattern on the other teeth that will provide info as well.

Quite often, I feel the ghost patterns tell me more than where I painted it.
 
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I think you're there, but do me a favor to confirm. Get all the paint off that ring gear including the adjoining teeth to the main pattern. Then apply as little as you can to only three teeth, in three different spots and then re run the pattern. I know this seems like a lot of extra work but I really want to see a more defined pattern and I think excess paint is skewing it some. When you run it, it will also leave a ghost pattern on the other teeth that will provide info as well.

Sounds good. I'll give that a go and post the pictures later today...

A slightly related subject: When I took this all apart there was no Bearing Thrust washer on the yoke assembly end and no washer for the pinion nut as per all the video's I've watched. I looked at the parts list and there are none shown. See below. Do I need them?

1701097292985.png
 
Sounds good. I'll give that a go and post the pictures later today...

A slightly related subject: When I took this all apart there was no Bearing Thrust washer on the yoke assembly end and no washer for the pinion nut as per all the video's I've watched. I looked at the parts list and there are none shown. See below. Do I need them?

View attachment 477496

There should be the washer between the yoke and the tail bearing. As far as the pinion nut, if it's a flange style nut, then no washer needed as it's built in. If it's a standard nut, then it needs a washer
 
There should be the washer between the yoke and the tail bearing. As far as the pinion nut, if it's a flange style nut, then no washer needed as it's built in. If it's a standard nut, then it needs a washer

OK. I'll try and find a Bearing Thrust washer but without a PN its tricky... NAPA couldnt find it.

Here are the pictures of todays pattern

IMG_2830.jpg


IMG_2832.jpg


IMG_2834.jpg


IMG_2836.jpg


run in three places as you suggested. Hopefully I didn't thin the paint out too much;