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I need help with Dana 35 rear end rebuild options

fizzlebottom

Member
Joined
Apr 21, 2019
Messages
53
Location
seattle, wa
Following up with my buggered rear end, I have deduced that the following events happened:
  1. The pinion seal leaked.
  2. Differential fluid somehow leaked into the threads of the pinion nut.
  3. That fluid acted like penetrating fluid.
  4. 155k miles of vibrations knocked the nut out of its perfectly fine home and forced it to drift away.
  5. Eventually the nut backed off enough that the pinion gear was able to become good friends with the carrier.
Here are some pretty pictures:
IMG_20190713_110322.jpgIMG_20190713_144538.jpgIMG_20190713_144547.jpgIMG_20190713_144554.jpgIMG_20190713_144653.jpgIMG_20190713_144708.jpgIMG_20190713_144727.jpg

  • I clearly need a new carrier.
  • I am fairly certain that I need a new pinion gear, but I want some opinions on that.
  • The ring gear looks completely untouched. Can I go without replacing if it is perfectly good condition?
  • Bearings and raced are all going to be replaced, but they all look and feel perfect.
I honestly have no desire to upgrade anything right now. Even with the widely hated 3.07 gears, this setup has lasted for 155k miles. I'd be fine with an equivalent setup lasting 155k as long as it isn't gonna cost more to stay stock. Is it economical to replace the carrier, pinion gear, all bearings and seals with equivalent stock units?

Let me know what you feel would be some good options for me that won't break the bank.
 

Jerry Bransford

TJ Guru
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Nov 9, 2015
Messages
12,061
Location
Escondido California
Don't install used gears, they are significantly harder to set up than new gears are. That is because they have become work hardened where they were touching and shimming them so they touched at those same points would be difficult. My recommendation is a new carrier, gears, a master setup kit, all sourced from the shop who will be installing them.

You want the installing shop providing all the parts used so there will be no warranty issues should something go wrong.
 
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Rob5589

Certified video trained differential rebuilder
Supporting Member
Joined
Aug 29, 2016
Messages
6,486
Location
W Sacramento, Kalifornia
Gears are shot, as are the bearings. Believe it or not, the carrier is likely ok to re-use. I would just smooth the burrs out with a grinder and/or file and clean up the cross pin bore, good to go. I would find a used one to install. No way would I spend any significant money on a 3.07 geared diff, no matter the tire size.
 
OP
F

fizzlebottom

Member
Joined
Apr 21, 2019
Messages
53
Location
seattle, wa
Gears are shot, as are the bearings. Believe it or not, the carrier is likely ok to re-use. I would just smooth the burrs out with a grinder and/or file and clean up the cross pin bore, good to go. I would find a used one to install. No way would I spend any significant money on a 3.07 geared diff, no matter the tire size.
I know dude. I'm really struggling with what to do. I know 3.07 gears are just not great for these vehicles and would love to change them out for something more ideal. I also do not want to mess with the front end right now, but understand that it very well might be inevitable.

If I can find a D44 from the right vehicle at a salvage yard for the right price, I'll grab it and deal with the front end right away. We'll see.
 
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fizzlebottom

Member
Joined
Apr 21, 2019
Messages
53
Location
seattle, wa
After doing some research, I'm tentatively landing on a new carrier, pinion & ring gear set, and master overhaul kit all by Yukon. Their prices beat everything else and they're local to me, so I shouldn't have a hard time finding what I need.
 
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Alex01

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Supporting Member
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Joined
Mar 23, 2018
Messages
3,217
Location
Martinez, CA, USA
After doing some research, I'm tentatively landing on a new carrier, pinion & ring gear set, and master overhaul kit all by Yukon. Their prices beat everything else and they're local to me, so I shouldn't have a hard time finding what I need.
If you haven't already purchased the gears @Squatch may still have a d44 or 2 sitting around....
 

BrunoPizz97

TJ Enthusiast
Joined
Jul 11, 2019
Messages
165
Location
long island
Following up with my buggered rear end, I have deduced that the following events happened:
  1. The pinion seal leaked.
  2. Differential fluid somehow leaked into the threads of the pinion nut.
  3. That fluid acted like penetrating fluid.
  4. 155k miles of vibrations knocked the nut out of its perfectly fine home and forced it to drift away.
  5. Eventually the nut backed off enough that the pinion gear was able to become good friends with the carrier.
Here are some pretty pictures:
View attachment 104124View attachment 104125View attachment 104126View attachment 104127View attachment 104128View attachment 104129View attachment 104130

  • I clearly need a new carrier.
  • I am fairly certain that I need a new pinion gear, but I want some opinions on that.
  • The ring gear looks completely untouched. Can I go without replacing if it is perfectly good condition?
  • Bearings and raced are all going to be replaced, but they all look and feel perfect.
I honestly have no desire to upgrade anything right now. Even with the widely hated 3.07 gears, this setup has lasted for 155k miles. I'd be fine with an equivalent setup lasting 155k as long as it isn't gonna cost more to stay stock. Is it economical to replace the carrier, pinion gear, all bearings and seals with equivalent stock units?

Let me know what you feel would be some good options for me that won't break the bank.
Following up with my buggered rear end, I have deduced that the following events happened:
  1. The pinion seal leaked.
  2. Differential fluid somehow leaked into the threads of the pinion nut.
  3. That fluid acted like penetrating fluid.
  4. 155k miles of vibrations knocked the nut out of its perfectly fine home and forced it to drift away.
  5. Eventually the nut backed off enough that the pinion gear was able to become good friends with the carrier.
Here are some pretty pictures:
View attachment 104124View attachment 104125View attachment 104126View attachment 104127View attachment 104128View attachment 104129View attachment 104130

  • I clearly need a new carrier.
  • I am fairly certain that I need a new pinion gear, but I want some opinions on that.
  • The ring gear looks completely untouched. Can I go without replacing if it is perfectly good condition?
  • Bearings and raced are all going to be replaced, but they all look and feel perfect.
I honestly have no desire to upgrade anything right now. Even with the widely hated 3.07 gears, this setup has lasted for 155k miles. I'd be fine with an equivalent setup lasting 155k as long as it isn't gonna cost more to stay stock. Is it economical to replace the carrier, pinion gear, all bearings and seals with equivalent stock units?

Let me know what you feel would be some good options for me that won't break the bank.
At least it held up, unlike my rear where it completely exploded into a million pieces. It sounded like a helicopter when I drove, it was like Jeep intentionally installed a helicopter mode in my Jeep. This was my old set up: Dana 35 rear with 3.07
I upgraded to the same Dana 35 but with a 4.10 and and an Aussie locker in the front diff. Now the Jeep has no problems spinning the 33” tires and I gained mpg I go 300 miles till my tank is empty.

655DBD1B-3EE7-44FF-B1B6-96C0219E4701.jpeg


C2D89898-7C7A-42DB-A4D5-167373EC9663.jpeg
 
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Squatch

Master Thread Derailer
Supporting Member
Joined
Oct 25, 2017
Messages
5,087
Location
Everett, Wash, United States
Here is a link to his add https://wranglertjforum.com/threads/d44-for-sale.24227/

@JMT do you have the d44 he mentioned shipping to texas?
Thanks for promoting my wares, @Alex01!!! ;) @fizzlebottom did contact me, and we're having some dialogue now. Appreciate that!

As for the other D44 that went to Texas, it went to a member who isn't quite as active on here as @JMT (but who is, right?) :unsure: :) He's a great guy, and said he'll be doing some build updates once he's made more progress. I haven't mentioned his forum name out of respect for his privacy. Figured it's his call to do so. :)
 
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JMT

The Jeep Guy
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Feb 27, 2017
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Washington
Thanks for promoting my wares, @Alex01!!! ;) @fizzlebottom did contact me, and we're having some dialogue now. Appreciate that!

As for the other D44 that went to Texas, it went to a member who isn't quite as active on here as @JMT (but who is, right?) :unsure: :) He's a great guy, and said he'll be doing some build updates once he's made more progress. I haven't mentioned his forum name out of respect for his privacy. Figured it's his call to do so. :)
I’m moving your direction at last @Squatch ! Leaving TX July 29 and should arrive Aug 5. WA, ready or not, here we come!!!
 
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Squatch

Master Thread Derailer
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Joined
Oct 25, 2017
Messages
5,087
Location
Everett, Wash, United States
@fizzlebottom's D35 troubles are over, as he is now in possession of my old D44 (thanks, @Alex01). ;) Now we just need to find him a matching geared (3.73) D30 for the front. There had been a couple locally on Craigslist that were cheap, but they're no longer listed. Maybe one will show up again soon. I'll be keeping an eye out for one for him. Nice guy!
 
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Alex01

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Joined
Mar 23, 2018
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Location
Martinez, CA, USA
Ideally you would want to swap the weaker cv shafts to ujoint but thats easy considering he has the shafts already under his jeep.