Help! Dana 35 Setup - Off-Road Forums & Discussion Groups
Jeep-Short Wheelbase All discussion of short wheelbase Jeeps: CJ, TJ, YJ and JK

LinkBack Thread Tools Display Modes
post #1 of (permalink) Old 09-11-2005, 10:55 PM
Posts: n/a
Help! Dana 35 Setup

I have run across an unusual problem while re-gearing my '88 YJ's rear end. I'm putting in a set of used 3.55s to replace the 3.07s that were in there for a 180,000 miles to better suit the 31" tires. The front end went as advertised with only the usual swearing and and wrench throwing. Both sets of gears looked to be in great shape. The problem started when I began reassembling the rear(all new bearings and such of course) I first used the same shim set up as it was before. Installed the pinion(with a setup bearing) and then went to put in the carrier and check the backlash - with the same shims it measured about .080! Well, okay, I can fix that right? So I start swapping shims from right side to left and before you know it I'm down to 0 shims on the right and and a whole bunch on the left and the backlash is now at .012. Still too much so I run a pattern and it shows the pinion a bit too far out so I bring it in .015 and check backlash - .060 good but pattern shows too close! I back the pinion out .005 and get a backlash of .008 and a pattern that is not ideal but at least pretty well centered face to flank. Anyway, I don't have anymore room for adjustment on the backlash and if I move the pinion out even a hair my backlash goes out of tolerance! Anybody ever encountered this before? Did I screw something up or is just a crappy set of gears? Any opinions would be greatly appreciated as I need to decide whether to go with this or just...go at it with a sledge! [img]/ubbthreads/images/graemlins/AR15firing.gif[/img]
Attached Images
File Type: jpg 1450270-JeepRearEndDrive.jpg (57.8 KB, 19 views)
Sponsored Links
post #2 of (permalink) Old 09-12-2005, 12:10 AM
Join Date: Dec 2001
Posts: 425
Thanks: 0
Thanked 0 Times in 0 Posts
Re: Help! Dana 35 Setup

Original carrier?
OregonSahara is offline  
post #3 of (permalink) Old 09-12-2005, 12:17 AM
Posts: n/a
Re: Help! Dana 35 Setup

Yep, the only thing I changed were the ring and pinion gears and all the bearings.
Sponsored Links
post #4 of (permalink) Old 09-12-2005, 04:45 AM
Keyboard Implanted
Rio_Grande's Avatar
Join Date: Jun 2000
Location: Southeastern Indiana
Posts: 4,767
Thanks: 3
Thanked 2 Times in 2 Posts
Re: Help! Dana 35 Setup

Unless I missed something you are now set up within specs?

They are used gears, if I had a decent patern and the backlash was right I say run them.

But I am only an amature at the gear swapping thing so somebody else chime in and tell this guy if I am wrong!!
Rio_Grande is offline  
post #5 of (permalink) Old 09-12-2005, 08:18 AM
Keyboard Implanted
mbalbritton's Avatar
Join Date: Mar 2002
Location: Winston-Salem, NC
Posts: 3,833
Thanks: 0
Thanked 0 Times in 0 Posts
Re: Help! Dana 35 Setup

I'm with Rio...Whst's wrong withwhat youv'e got now? other than you've wasted....sorry spent this muchtime on a d35 already......
mbalbritton is offline  
post #6 of (permalink) Old 09-12-2005, 08:39 AM
Posts: n/a
Re: Help! Dana 35 Setup

I guess I'm just very paranoid about putting this back in with all those shims on the ring side of the carrier...just doesn't seem right. I've been doing some more research(should have done before!) and it appears on the 35 you need a different carrrier when you go higher than a 3.31 gear set. I guess on the Dana 30 the cutoff is anything above 3.55 which is what I remember seeing and just assumed they were the same. I'm thinking this is probably the problem and I need to get a new carrier ASAP(Yukon has one for $58). [img]/ubbthreads/images/graemlins/tongue.gif[/img]
Attached Images
File Type: jpg 1450337-JeepRearEndBearing.jpg (56.6 KB, 12 views)
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Off-Road Forums & Discussion Groups forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome