Topic: ring gear problems

[arkypyro]

I just wanted to mention that I have had an interesting problem.  I bought my 97 TJ a year ago with 70K miles on it.  I just recently started to notice some rear end (dana 35) noise and once while driving down a dirt road the rear end loaded up and then popped on me.  I pulled the rear cover to check things out and found the cause.  The load and pop was caused by a ring bear bolt head getting caught between the ring gear and rear cover.  The other noise was cause the 4 ring gear bolts were loose to the point that I could turn them with my fingers.  Yes I said 4 ring gear bolts.  The others are all broken. There was only one bolt head in the case.  I have put about 18K on it since I got it and have had no other problems with the rear end.  I am just gonna drill out the broken bolts and replace all of them.  I don't see any need to do anything more.  I know that I will probably hear that I shouldn't put any money into a D35, but I think that the D35 get a bad rap much like the 2.5L.  I am in Western Arkansas and most of my off road is on dirt or in mud, and I have the front end locked so the rear end doesn't get to badly abused.  Don't really need advice, just thought it was interesting that the rear end has held up the way it has.  I do have a winch question but I will put that in another post.

[SMC4WD]

As far as the D35 axle having a bad rap...  It's well deserved.  The spider gears are whats gonna get ya.

As far as the ring gear bolts coming loose (and off).  That sounds like a loc-tite issue.  Has the R&P changed prior to you getting it?  I couldn't imagane that being a factory issue, not with 88K on it.  

As long as there weren't any major damages inside.  Replace the bolts (use loc-tite) and call it good!!  But save up...  That D35 will get ya everytime!!

[Jeffy]

It definatly sounds like lock-tite issues.  Like they used too little or didn't even bother with them.  If the bolts got between the gear teeth there they are probably toast.

The D35 is ok if you don't plan on doing much with your Jeep.  Start to push it and it will break.

Oh and if you think the D35C is just getting a bad rap, check out this thread: http://www.4bangerjp.com/forums/viewtopic.php?t=467

[arkypyro]

This isn't a lok-tite issue.  The 4 bolts are snapped not out.  This is the first time I have had the cover off.  Since the other 3 bolt heads weren't in there I am guessing that maybe it was a torque issue and happen during some previous assembly.  Don't know.  Just curious if anyone else had had the problem.  I will check out the thread and let you know what I think.

[Jeffy]

What usually happens is that the bolts might walk out a bit then the play in the ring gear will snap the heads off.  The other senario is that the bolts were used and there already stretched.  Or else, it could have run low on oil and heated up. Then the bolts snapped.

In any case, unless you've got an extended warranty, it would probably be cheaper to buy a complete D35 then to regear your old one again.  D35's should go for $3-500.  That is, unless you want to just regear both ends.

[getstucksome]

that happened in my 35, or at least part of it did.  i blew mine out at uwharrie, all bolts snapped into 3 peices, shaft, shaft, hex head, and the bottom of the shaft of 3 bolts stayed in the ring gear.  needless to say, i swapped it out for an 8.8.  sorry to hear about your axle though.  u can get em cheap

[arkypyro]

Where can I find a chead D35.  I need one badly.  I finally lost all the ring gear bolts and tore into it tonight.  Ring and pinion are shot.  The shafts appear to have been replace as they have yellow marking crayon on them, and they are worn our.  The axle spline and the side gears are soworn that you can damn near jump a spline with them.  I When I lost my ring gear I also scored my carrier. As yo can see I have gotten mighty expensive if I replace everything.  I had already decided to go with an aussie locker instead of spider gears as they aren't that much more, but this puts me in the $700-$800 range not counting paying someone to set it up for me.  I have a quote of $150 for the set-up.  If I could find a good complete axe I would go that route and save my money to build a D44 in my own time, but I have had no luck around here finding either a D35 or a D44.  If anyone can help me please let me know.

[Jeffy]

I'd look at all the axle options not just Dana 35C and D44.  You'll have to go search at a U-Pull-It.  Dana 44's are good but so is a Toyota 8" or even a Taco 8".  You can find D44's in Isuzu Rodeo's and Amigo's occasionally. They generally have deeper gears starting around 4.27:1 and 4.56:1.  Ford Explorer with an 8.8" is also a good choice.  4.10's are available in the V8 Limited's.  Then you have the 70's LTD's with their 9".  They'll need regearing but gearing is cheaper for a 9 since you can just swap centers.

Some of these axles are 5 on 4.5 while some are 5 on 5.5 and 6 on 5.5" bolt patterns.  Still it gives you a large selection.

If you still want a D35c and throw in stock gears then I suggest getting a complete housing.  Usually around $300.  Personally, I'd use this to upgrade.  It happened once and could happen again.

[arkypyro]

I called all over Arkansas and Oklahoma and found only 3 D35's ranging from $775 to $1000 and no suitable D44's.  I decided to rebuild my original and started hunting parts.  I found a real gem.  I called Randy's Ring and Pinion based on a local recommendation.  These guys know what they are doing and talking about.  Jeremy was very helpful when I told him that I needed everything except the axle houseing, Yoke, and diff cover.  He put everything together including Master install kit, new axles, Yukon ring and pinion, Lok-rite locker, carrier, all bearings and seals.  Price?  I was shocked when he told me... $817.85.  He then gave me a bit of a break so that with shipping it will come to right at $850.  It will ship out of the warehouse today and be on my doorstep Thursday.  I have to pull the housing out from under my rig but a local shop will install and set up all the components for $150.  I know that many of you will give me hell about putting a grand into a D35 but  it will truly be like new and this is my daily friver so I am out of action until I get this done.  I don't have time to do anything fancy, and I don't see any way I could do an entire project like that for a grand, especially since I don't have access to a good welder, so I would have to hire all the fabrication out.  I appreciate all the help and advice, I know I may have let some of you down, but lets remember "Different stokes for different folks".

[SMC4WD]

It's too late now, but you should have asked him about a Super 35 kit.

You still needed to buy axles, but you could have gotten 30 spline axles instead of 27 spline.  You would still need to buy a carrier, but you could have gotten a stronger one (sorry, more money), but gotten a Detroit, or an ARB.

I don't think that Lock-right (or any equivilent) offers 30 spline side gears.

The R&P guys are truly nice guys...  It's good that they helped you out.

[jagular7]

Since you are in the western Ark. region, give a look over the border to the Oklahoma 4wd group. Here is a link to the forum. http://www.okfwda.org/
Then there are some Jeep groups like KC Jeep (http://www.kcjeepclub.org/home.php) which may have some help for supplies for your Jeep.
Down in Pittsburg, KS at the Pittsburg State University, there is a local 4wd group of 'kids'. Not sure if there is a forum, but the group goes to KanRocks and Disney. Up a little in Ft. Scott/Nevada MO area is the BrushBeaters 4x4 club which is mostly TJs.  KanRocks has a forum for you to use to help find things. TrailKrawlers is another but they are near Manhattan, KS.
However, down in Disney, OK, there is Hogan's RV Park. Hogan has lots of parks for about anything that will wheel at Disney. Real nice easy going type of guy as I've been told. http://www.ksrockspark.org/phpBB2/index.php  http://trailkrawlers4x4.org/forum/index.php


Sorry to read of the effort you have to do.

[Bounty Hunter]

You can get a D44 out of the rear of a '93+ Isuzu Amigo with disc brakes and 4.10 R&P.  It is 6lug so a Waggy front D44 makes a great match.

I've got a D35 with 4.10 out of an MJ for sale.