Dana 35 Pinion Gear Destroyed

[EstoKarl]

Hey everybody,

1998 TJ Sahara 4.0 5speed, Dana 30 front, Dana 35 rear, 3.76 ratio?
I opened up my rear diff today to change the fluid. This is what I found. Video is attached below.

My question is what causes this and how do I go about replacing the pinion gear? If I pull on the wheels, the axle shafts do move in and out about 1/8 in. Is that normal? I also had a grinding noise from the rear when turning right which I suspect was the result of this. The ring gear and everything else looks to be in good shape, no chipped teeth or anything, just the pinion.

Thanks for all the help again! - Karl

 

[Daryl]

Cheapest way out of this is go buy a used axle assembly from a wrecked Jeep. Make sure the gear ratio matches yours.

 

[EstoKarl]

Cheapest way out of this is go buy a used axle assembly from a wrecked Jeep. Make sure the gear ratio matches yours.

Why? What makes it so expensive?

 

[never monday]

Why? What makes it so expensive?

You need a new gear set and have it set up

 

[Jerry Bransford]

X2, you can't just install a replacement pinion gear as the R&P gears are matched and lapped together. Installing a new set of gears requires a complete gear setup which is neither easy nor inexpensive.

 

[eastbloc]

Why? What makes it so expensive?

Regear with parts will be roughly $1000
As for Dana 35, in some parts of the US people cant get rid of it even for the price of scrap metal

 

[qslim]

As for Dana 35, in some parts of the US people cant get rid of it even for the price of scrap metal

Yeah, I have a 35 that I just took out for a swap. Not a lot of interest. Hell I'd give it to the OP for free if he wanted to come get it.

 

[qslim]

Why? What makes it so expensive?

I have a new set of gears on the shelf, not sure if I'm going to do it myself or not because it's been a long time. I've been quoted $1,000 - $1,300 in labor to do both axles. Like @eastbloc said, D35s are a dime a dozen & an axle swap is very straightforward. 3.73 gears are also very common.

 

[EstoKarl]

Thanks for the advice guys! Looks like I'll have to look out for another axle. An axle swap should be as easy as unbolting and bolting back in, right?

Thanks for the offer @qslim but I'm a bit far in Connecticut.

 

[qslim]

Thanks for the advice guys! Looks like I'll have to look out for another axle. An axle swap should be as easy as unbolting and bolting back in, right?

Thanks for the offer @qslim but I'm a bit far in Connecticut.

Yeah that's a bit of a hike.

Yes, the axle swap is strictly a bolt-in affair. If you aren't changing control arms & everything else its really simple.

 

[never monday]

Thanks for the advice guys! Looks like I'll have to look out for another axle. An axle swap should be as easy as unbolting and bolting back in, right?

Thanks for the offer @qslim but I'm a bit far in Connecticut.

Look for an axle from an 04-06 LJ. It’ll be about $1000 but already geared 3.73 and a D45

 

[qslim]

Look for an axle from an 04-06 LJ. It’ll be about $1000 but already geared 3.73 and a D45

You mean Dana 44 or Dana 35?

A Dana 44 is is always an option, that's exactly what I'm doing now to my Sahara. Found one out of a wrecked '04 LJ.

If the OP wants to keep it stock & doesn't need the Dana 44 he can probably get a Dana 35 with 373s for a lot less.

 

[Nickgsjeep]

Took forever to get rid of my Dana 35 when I switched to a 44. Practically had to pay the buyer to come get it. You should be able to find one relatively cheap up near you. Cheaper than a regear anyway.

 

[qslim]

Took forever to get rid of my Dana 35 when I switched to a 44. Practically had to pay the buyer to come get it. You should be able to find one relatively cheap up near you. Cheaper than a regear anyway.

Same deal here. When I found my Dana 44 the guy was adamant that the front Dana 30 was part of the deal. So now I have a Dana 35/Dana 30 in 3.73 that no one around here wants.