Dana 35 Re-gear Pattern

[TJX02]

Throwing 4.88's into my Dana 35 (from 3.07). Made my inner pinion setup race. Extracted the factory pinion shim, annoyingly between the pinion head and bearing (0.042).

Built a stack equal to the factory shim and threw it behind the inner pinion race. Thick factory carrier shims wouldn't fit with my new carrier (was below carrier break), so made a new stack.

Got my backlash at 0.008. First pattern looked a bit shallow so added 6 thousandths onto the stack (0.048). This pattern has me pondering a bit. On the one hand, it doesn't seem deep but on the other hand, there's a hard line on the root of the tooth on both the drive and coast sides.

Does pattern look deep?

 

[Blackjack]

You are just a tiny bit deep.

 

[Foxhound67]

I'd take a thou, maybe 2 out and run another pattern

 

[TJX02]

Removed some depth, here's the pattern that I went with.

 

[TJX02]

Only issue I'm stuck on is the crush washer. I actually have a solid spacer kit on hand but went with the crush so that I could use my impact wrench... only my 700lb impact wrench is not strong enough.

I think i'm just gonna jack the Jeep up higher and use the torque wrench on the solid spacer with my setup nut. Will resume on Saturday.