has anyone done their own gear change?

[JeepN95YJ]

Question for anyone in this post who recommended swapping the D35:

Who here has personally broken their D35? And what broke?

Burning up a limited-slip is common for any axle if you constantly let one wheel slip while wheeling. You can burn up spidergears and crosspins the same way in an open diff. This is not inherently a flaw of the D35.

 

[JeepN95YJ]

Good advice so far as far as doing your own gears.

There are literally millions of D35s out there that have NEVER broken a shaft, but if you read the internet, you're going to break it pulling into your driveway. Personally, I wheeled a D35 in my YJ on 35s, 4.10s and lockers for 4 years in OH, KY and TN. This was back in the late 90s when 33s were still big tires. I never broke anything on my D35during this time frame. I wheeled at least once a month, drove it 3+ hours from home and back plus I drove it everyday to work. I put over 80,000 miles on that combo. I also guided for Jeep Jamboree with this Jeep and used it as a testbed for my offroad shop.

Did I ever see a D35 break? Yep. Probably saw at least 6 break. Common denominator with every one was a driver that had a make it or break it attitude. Half of the time they bent their housings as a result of the beatings they would dish out. I tried to encourage the attitude of "love your jeep" and treat it that way. I wouldn't hesitate to drive a D35 equipped Jeep for expo travel and light wheeling on 33s. I'd probably run 4.56 gears but 4.10s would be ok.

Do I still run a D35. No. I have a Ford 9 inch. I built my current Jeep for a customer back in 2001. He was one of those make it or break it guys. He bent his D35 housing when the Jeep was only 3 weeks old by running off the road and up a telephone pole. This Jeep now has about 95k on it and the axles are still going strong.

Be honest with yourself about how you will be using the jeep and then spend money accordingly. Forget about the advice for D60s (I've run them as well). Absolutely absurd unless you are rockcrawling.
:ylsmoke:

 

[slimtwo]

+1
Saves you the headaches of trying to figure out why the pattern isn't right. .
Gears require a bunch of specialized tools though. Bearing puller is always nice. Hydraulic press, inch-lbs dial (or beam) torque wrench, dial indicator, micrometer/caliper, etc... If you're really self-motivated and are willing to take the time to do it to spec. it's not that bad. Otherwise, it's not worth it if you can find someone to install them for $75-200. The setup bearings really help though. A case splitter is also very handy. Most shops will pull and press bearings for you if you don't have a press. It's just time consuming to have to pull then drive the carrier to the shop and then drive back then drive to get them pressed.

If it's your first time then I'd estimate a day for each axle.

Thank you very much for your input, I really appreciate it. My neighbor has all the specialty tools you mentioned, except I’m not sure about the case splitter, what is that used for? My neighbor has also offered his services as my technical advisor when I need him.

As far as doing it to specifications, I don’t know any other way to do it. And if I can’t do it, then I will pay the experts to do it. When it comes to my rig, I will not cut corners. If I am putting my faith in it to get me out to my play area and back home again, it has to be right. I enjoy the challenge, but I’m not afraid to admit it when I can’t do it.

 

[slimtwo]

Good advice so far as far as doing your own gears.

There are literally millions of D35s out there that have NEVER broken a shaft, but if you read the internet, you're going to break it pulling into your driveway. Personally, I wheeled a D35 in my YJ on 35s, 4.10s and lockers for 4 years in OH, KY and TN. This was back in the late 90s when 33s were still big tires. I never broke anything on my D35during this time frame. I wheeled at least once a month, drove it 3+ hours from home and back plus I drove it everyday to work. I put over 80,000 miles on that combo. I also guided for Jeep Jamboree with this Jeep and used it as a testbed for my offroad shop.

Did I ever see a D35 break? Yep. Probably saw at least 6 break. Common denominator with every one was a driver that had a make it or break it attitude. Half of the time they bent their housings as a result of the beatings they would dish out. I tried to encourage the attitude of "love your jeep" and treat it that way. I wouldn't hesitate to drive a D35 equipped Jeep for expo travel and light wheeling on 33s. I'd probably run 4.56 gears but 4.10s would be ok.

Do I still run a D35. No. I have a Ford 9 inch. I built my current Jeep for a customer back in 2001. He was one of those make it or break it guys. He bent his D35 housing when the Jeep was only 3 weeks old by running off the road and up a telephone pole. This Jeep now has about 95k on it and the axles are still going strong.

Be honest with yourself about how you will be using the jeep and then spend money accordingly. Forget about the advice for D60s (I've run them as well). Absolutely absurd unless you are rockcrawling.
:ylsmoke:

Thank you Jerry for your comments, they were quite refreshing. I was beginning to get a little discouraged. I didn’t think I would hear even one positive comment about the D35. But you are right on with your perspective. It is about how you drive that determines how your equipment holds up. I don’t drive my rig hard when I’m out on the trail, because it has to get me home, and then to work on Monday, my jeep is my daily driver. I’m more of an adventurer than a rock crawler anyway. In my 20 plus years of off-road adventures, I’ve found the term “4 on the floor” works best for me; pick a good line and keep all 4 tires on the ground. That has gotten me through many a technical trail, and with open diffs. I might still look to see if there are any listings for used Rubicon axles for sale, however, if I don’t find anything, I may consider going ahead with my plans to upgrade my current axles, and I’ll do it using the technical assistance from all of you forum folks. Thank you all so much!

Happy trails!

 

[jeffy]

Thank you very much for your input, I really appreciate it. My neighbor has all the specialty tools you mentioned, except I’m not sure about the case splitter, what is that used for? My neighbor has also offered his services as my technical advisor when I need him.

As far as doing it to specifications, I don’t know any other way to do it. And if I can’t do it, then I will pay the experts to do it. When it comes to my rig, I will not cut corners. If I am putting my faith in it to get me out to my play area and back home again, it has to be right. I enjoy the challenge, but I’m not afraid to admit it when I can’t do it.

If your neighbor has the skill then just having him watch over and or just check over your work it would be of great help. If you're not in a hurry and have no timeline then I'd do the gear change.

I should have called it a 'case spreader'. It's used to stretch the differential housing ever so slightly. The differential won't just slip in and out easily. The spreader will give you the necessary clearance to drop it in and out. It's not 100% necessary but makes life easier.

 

[slimtwo]

If your neighbor has the skill then just having him watch over and or just check over your work it would be of great help. If you're not in a hurry and have no timeline then I'd do the gear change.

I should have called it a 'case spreader'. It's used to stretch the differential housing ever so slightly. The differential won't just slip in and out easily. The spreader will give you the necessary clearance to drop it in and out. It's not 100% necessary but makes life easier.

So I assume the two holes on each side of the "case spreader" match up to the diff holes in the housing. How someone came up with that is amazing. Is that for Volkswagen engine work?

As far as having a timeline, I would need to get this done in a weekend; otherwise I will be walking to work. Which would be healthy an all, but not my first choice. I will make sure to have everything I need gathered up, and to have done my homework before I start. Thanks for sharing what the tool was for.

Happy trails!

 

[jeffy]

So I assume the two holes on each side of the "case spreader" match up to the diff holes in the housing. How someone came up with that is amazing. Is that for Volkswagen engine work?

As far as having a timeline, I would need to get this done in a weekend; otherwise I will be walking to work. Which would be healthy an all, but not my first choice. I will make sure to have everything I need gathered up, and to have done my homework before I start. Thanks for sharing what the tool was for.

Happy trails!

Yeah, the spreader bolts to the housing the stretches the opening ever so slightly. It's for Dana axles. I've done it without one but it's a PITA since the differential is really tight in there. You usually have to lever it out with a pry-bar and hammer to get it in.

If you've got all the tools and help from your neighbor, you should be able to get it done in around 4-6hrs a diff. Might still take two days unless you work all day. The biggest time consumer is getting the pattern right. If you're lucky, or if your gears actually tell you (+1.+2, +3, etc...) the shim thickness then you could have it done pretty quick.

 

[Eric S.]

Question for anyone in this post who recommended swapping the D35:

Who here has personally broken their D35? And what broke?

Burning up a limited-slip is common for any axle if you constantly let one wheel slip while wheeling. You can burn up spidergears and crosspins the same way in an open diff. This is not inherently a flaw of the D35.

I changed mine to a D44 before the D35 broke. I go out exploring alone often and didn't want the added risk. I was out with a guy that had 31" on his XJ and broke an axle shaft. Hi was just turning around backing the jeep up a smooth rock face (maybe 45 degrees at the most) He got about half the Jeep on it without generous use if the throttle and snap that was it. I was really surprised it snapped there. After seeing that the axle went on my crap list

 

[jeffy]

I changed mine to a D44 before the D35 broke. I go out exploring alone often and didn't want the added risk. I was out with a guy that had 31" on his XJ and broke an axle shaft. Hi was just turning around backing the jeep up a smooth rock face (maybe 45 degrees at the most) He got about half the Jeep on it without generous use if the throttle and snap that was it. I was really surprised it snapped there. After seeing that the axle went on my crap list

Many times people end up twisting it elsewhere and later stressed it just enough that it breaks.

 

[Stumpalump]

To get a stuborn carrier out with out a spreader you need to shove a prybar against the ring gear to stop it from spining. Once it's held in place you spin the pinion by the yoke and it drives the carrier right out.

 

[BigAl]

Good advice so far as far as doing your own gears.

There are literally millions of D35s out there that have NEVER broken a shaft, but if you read the internet, you're going to break it pulling into your driveway. Personally, I wheeled a D35 in my YJ on 35s, 4.10s and lockers for 4 years in OH, KY and TN. This was back in the late 90s when 33s were still big tires. I never broke anything on my D35during this time frame. I wheeled at least once a month, drove it 3+ hours from home and back plus I drove it everyday to work. I put over 80,000 miles on that combo. I also guided for Jeep Jamboree with this Jeep and used it as a testbed for my offroad shop.

Did I ever see a D35 break? Yep. Probably saw at least 6 break. Common denominator with every one was a driver that had a make it or break it attitude. Half of the time they bent their housings as a result of the beatings they would dish out. I tried to encourage the attitude of "love your jeep" and treat it that way. I wouldn't hesitate to drive a D35 equipped Jeep for expo travel and light wheeling on 33s. I'd probably run 4.56 gears but 4.10s would be ok.

Do I still run a D35. No. I have a Ford 9 inch. I built my current Jeep for a customer back in 2001. He was one of those make it or break it guys. He bent his D35 housing when the Jeep was only 3 weeks old by running off the road and up a telephone pole. This Jeep now has about 95k on it and the axles are still going strong.

Be honest with yourself about how you will be using the jeep and then spend money accordingly. Forget about the advice for D60s (I've run them as well). Absolutely absurd unless you are rockcrawling.
:ylsmoke:

anti religion posts are stickly moderated here so tread lightly. Several jeep forums have already adopted the 11 commandment, 'thou shalt not run a D35'

I have got to agree with you, ihave seen many dana 35s abused and not broken. For 33 tires I wouldn't hesitate to run it open or locked

 

[nwoods]

Bruce, I would argue that locking your diff is easier on the rig (and the trail) than running open. Being locked requires much less use of throttle and momentum to get through/over a given obstacle. BUT, I would strongly encourage you to run a selectable locker (e-locker or ARB style) rather than something like a TruTrac, because the D35 axle is ultimately going to be the fusable link in your setup.

If you are on MJR's forum, hit up Rat Patrol (Kurt) for more info as well. He's very experienced at regearing Jeep diff's, and offers it as a service, cheap. It can still be a father and son thing, but at Kurt's house under his guidance. You'll be in an out in just a few hours.

 

[slimtwo]

Bruce, I would argue that locking your diff is easier on the rig (and the trail) than running open. Being locked requires much less use of throttle and momentum to get through/over a given obstacle. BUT, I would strongly encourage you to run a selectable locker (e-locker or ARB style) rather than something like a TruTrac, because the D35 axle is ultimately going to be the fusable link in your setup.

If you are on MJR's forum, hit up Rat Patrol (Kurt) for more info as well. He's very experienced at regearing Jeep diff's, and offers it as a service, cheap. It can still be a father and son thing, but at Kurt's house under his guidance. You'll be in an out in just a few hours.

Hello Nathan,

It's been a long time. That sounds reasonable, it makes sense that you wouldn’t have to be as heavy on the throttle when you are locked, and I don’t like to romp on it anyway. As for my locker of choice. I am looking at the “Eaton” E-locker as opposed to the ARB. I was looking at a display at one of the shows, and the e-locker looked like it worked well, and was well engineered.
I will see if I can look Kurt up, seems I've seen that name on posts before, having that kind of expertise over your shoulder sounds good. Thank you for your input.

Happy trails!

 

[slimtwo]

Well my Son and I attended the “4 Wheel truck fest” in Ontario Ca this last weekend, where I was able to purchase a set of G2 4.56 gears, and an Auburn ECTED selectable locker. I saved about $150.00, more if you include what I would have spent on shipping. So now, with the advice and help from everyone on the forum who offered their expertise, my son and I will dive in and hopefully come out with a successful gear change.

Thanks again!

Happy trails!

 

[GP'd]

Awesome! Post pictures and good luck!