Rear axle gears exploded, what happened?

[Robb]

The daughter was driving home on the highway last night, everything was good and fine and running well except mid commute she gave the Jeep gas there was a big clattering. She pulled over, called me and the Jeep idled fine, went into reverse fine, but in drive it sounded like a box of rocks being shaken. Huge metallic clattering. Wouldn't move forward in drive. I had the Jeep towed to the shop and I guess the gears basically came apart, exploded, grenaded.
I've never heard of anything like this outside a hotrodded car or dragstrip abuse. What happened? This a Dana 35 thing?
The TJ is a 97, 125xxx miles 4.0 auto. Rear is a Dana 35, 3.07's. My daughter is not the hotrod type, I'm certain she wasnt abusing the Jeep, the roads were dry, she wasn't in 4x4.
I'm curious what the heck happened, whether it's a freak deal or what.
And yes, I'm shopping for a new axle, if you're in Colorado and know of one, please contact me.

 

[BKDinTexas]

Pinion seal failed. Diff oil drained out. Gears got too hot and seized up



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[AndyG]

A 35 is out there.

And no, that’s not even remotely common.

 

[Daryl]

The differential/spider gears most likely failed. Common failure for stock Dana 35’s.

 

[Boinked]

The daughter was driving home on the highway last night, everything was good and fine and running well except mid commute she gave the Jeep gas there was a big clattering. She pulled over, called me and the Jeep idled fine, went into reverse fine, but in drive it sounded like a box of rocks being shaken. Huge metallic clattering. Wouldn't move forward in drive. I had the Jeep towed to the shop and I guess the gears basically came apart, exploded, grenaded.
I've never heard of anything like this outside a hotrodded car or dragstrip abuse. What happened? This a Dana 35 thing?
The TJ is a 97, 125xxx miles 4.0 auto. Rear is a Dana 35, 3.07's. My daughter is not the hotrod type, I'm certain she wasnt abusing the Jeep, the roads were dry, she wasn't in 4x4.
I'm curious what the heck happened, whether it's a freak deal or what.
And yes, I'm shopping for a new axle, if you're in Colorado and know of one, please contact me.

First is it common? No its not common. But it does happen. This is why you should regularly change the fluid in the differential.

This also gives you the opportunity to look at the gears for something that doesn't look right. Spider gears do wear and need to be replaced. Im not saying that happened in your case. But it is a likely suspect.

I would look at craigslist in your area. A stock dana 35 with 3.07 gears are cheap. In Arizona you can't give them away.

 

[Fouledplugs]

Often, Wrangler owners do not want to keep the small Dana 35 under their Jeeps. People like to upgrade them, so you should be able to find one very cheap.

 

[Robb]

Pickings in Denver are thin. I did find a 35 with 3.73s and think I'll go that route. I'll just pull the front shaft and make it a 2 wheel drive for the short term. I wish I wasn't on a budget but that's my life.

 

[tworley]

https://denver.craigslist.org/pts/d/denver-jeep-tj-dana-35-and-hp-dana-30/6872816459.html
https://denver.craigslist.org/pts/d/brighton-jeep-wrangler-tj-axles-456/6865004249.html
https://denver.craigslist.org/ptd/d/erie-1997-jeep-wrangler-tj-part-out/6858622053.html
Jeeps unlimited in Erie is moving to Grand Junction I hear. You might be able to get a replacement for cheap as they are clearing shop

 

[Robb]

$800.00 for a 35 with 3.73s.
I'd say that was steep, but that's where I'm going today to get the axle. The daughters jeep is a DD and I can't wait for a deal to come along.

 

[RaymondT]

The questions needs to be asked... what specific parts are actually damaged? Spider/end gears? R & P? axle shafts? the carrier? Some shops see pieces and talk like it's a catastrophic failure for dramatic effect.

Not uncommon for the spider gears to fail, even with stock sized tires. These kits are cheap and easy to replace.

 

[glwood]

This link above looks like a decent choice for a budget replacement:

https://redirect.viglink.com/?forma...t= Jeep tj Dana 35 and hp Dana 30
If you go the more expensive route of the one with the 3.73 gears, it costs more now, and once your daughter feels the difference of the new gear ratio, she'll want to regear the front...there goes the budget...

 

[Robb]

Visited the shop today, I guess the bearings were trashed, allowed the axles to move inward making contact. The spider gears, ring gear, etc were all loose inside the housing, as in slopping around with little pressure from your foot.
Anyway, the new rear with 3.73s are in. Seems to run well. Thanks for all the responses.