I've been regearing my Dana 35 rear, managed to do everything at least twice and now I'm trying to fit the axles in. I'm stumped. I have the c clips on but now there isn't room for the pin to drop through. The axles won't move out far enough. What did I screw up?
Help putting axles back in Dana 35
- Thread starter Verndawg
- Start date
Those pinion gears look ugly to me. The left looks as if the C clip is recessed just slight of the surface at the bottom but just slight past up top. Im no expert but I have done a couple 35's. If the clips are new Id double check them for burrs or cupping from when they were stamped. It looks like your only a few Th short of the pin going in. Surely some of the more seasoned guys will chime in.
@machoheadgames knows of some hardened spider gear sets that don't explode like the cheaper ones. I'd think about installing those and then just clearancing the ends of the axleshafts if needed
So all of the gears are brand new, including spider gears. Also forgot to mention it's also a new Trac Lok clutch pack. Only the axles and c clips are old.
KennethS
TJ Expert
I've never seen the inside of one of those so I don't know anything about them, but it looks like that tab isn't sitting down into the recess in the carrier.
Thank you! I don't mind pulling it all apart again, I think you spotted the problem. I don't mind pulling it all apart again as long as I have some direction. Sometimes it can be difficult to do this by myself. When I was younger I always had a buddy to help out and troubleshoot.
As for the gears, I wasn't too happy to see how rough the surfaces were, but I don't have options about where to buy from as I'm in a small town in northern BC. Most of my parts are ordered online, lots from Just Jeeps in Toronto.
As for the gears, I wasn't too happy to see how rough the surfaces were, but I don't have options about where to buy from as I'm in a small town in northern BC. Most of my parts are ordered online, lots from Just Jeeps in Toronto.
AAAARRRGGGHHHH!!!!!! I took the carrier out, checked the clutch packs, put it all back together. Put it back in with one of the wheels bolted on and still it's the same. I want to take the grinder to the axles, but I know there has to be an explanation! Maybe I'll try with the old parts in there. Or maybe just spend all my money on beer instead of the Jeep.
Turns out it it's the parts. Took out the new spider gears to compare...different thickness. Just checked my order and it said it is for my Jeep. Crown Automotive. Will put the old gears in and reach out to the supplier. Hopefully get it all back together tonight.
Success!!! Put the old spider gears in and got everything together. Test drive around the neighborhood, gears didn't have any whine or grinding noises. Definitely a bit more pep. Next weekend I'll do the front gears. Should be simple. Maybe.
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