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Unread 04-19-2013, 07:17 PM   #1
kputcha1
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DANA 35 differential question

I have a 4 cylinder 5 speed 1995 YJ and I was working on the rear DANA 35 differential and I broke the pinion shaft lock bolt in the differential case. I tried drilling out the bolt but I may have toasted the threads which would hold the bolt in the case. The pinion and ratio ring are okay, but I think I'll need to replace the case. This may be a stupid question but, I was wondering if I were to buy a used (DANA 35) rear differential case that was on a 1991 6 cylinder, 5 speed YJ (with 3.07 gear ratio) would I be able to change out the gears in the case back to 4.11? I greatly appreciate any advice at this moment.

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Unread 04-19-2013, 07:25 PM   #2
Anticanman
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First of all, welcome.

Second, no. There are two things holding you back. First is the fact that the carriers are not interchangeable on two levels. There is a carrier break from 3.73-4.10. There is also a difference between the pre '93 and post '93 Dana 35 carriers in terms of gears. Second is not an insult, but the expertise it takes to install gears is beyond even my scope of wrenching to be done on a whim.

Find a matching axle with 4.10 and hang on to your original rear yoke because you may need to swap it onto another axle.
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Unread 04-19-2013, 07:53 PM   #3
kputcha1
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Thank you very much for you input. I would prefer not to replace the entire axle due to the expense it would cost me. Money is a bit tight for me at the moment, so do you think keeping an eye out for a used DANA 35 carrier with the 4.10 gear ration which fits my wrangler model sound practical?
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Unread 04-19-2013, 08:39 PM   #4
Anticanman
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It's going to cost a whole lot more to set up the gears than to install the whole axle.
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Unread 04-19-2013, 08:40 PM   #5
Kaiser-Willys
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If you change the rear gear ratio you HAVE to change the gears in the front diff at the same time. Not doing so will cause serious drivetrain damage.

If you did booger up the threads for the cross pin shaft retainer bolt, I would pull out the carrier and Heli-coil that hole.

Good luck!
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Unread 04-19-2013, 10:34 PM   #6
Joe Dillard
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Quote:
Originally Posted by Kaiser-Willys View Post
If you change the rear gear ratio you HAVE to change the gears in the front diff at the same time. Not doing so will cause serious drivetrain damage.


To say you HAVE to, is inaccurate. Here's a couple reasons why......if he's running stock driveline components, as long as he doesn't put it into/drive it in 4WD, he'll be fine since no power is being applied to the front axle. That, or simply remove the front drive shaft & you'll eliminate a possibility of having a ratio difference issue.

Make sense?
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Unread 04-19-2013, 10:48 PM   #7
ghetdjc320
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Just FYI the break on ratios for the dana 35 is 3.55 and 3.73 on the dana 30. Dana 35 3.55 and up and 3.54 and down.
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Unread 04-19-2013, 11:46 PM   #8
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Originally Posted by ghetdjc320 View Post
Just FYI the break on ratios for the dana 35 is 3.55 and 3.73 on the dana 30. Dana 35 3.55 and up and 3.54 and down.
Right. Typed it wrong. Thanks!!
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Unread 04-20-2013, 04:13 AM   #9
bogleparsons
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I have a Dana 35 sitting in my garage complete brakes to brakes.

Too bad you can't come get the damn thing.
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Unread 04-20-2013, 07:12 AM   #10
soonermatt
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To clarify on price: I sold my functional, 4.10 Dana 35 for $100 outright.

Cost to install gears in new axle: $200
Cost of new gears: $200
Cost of used axle: $250
Cost of bearings, inner and out: $150
Oil: $15
And there's even more


As you can see, dicking with axles gets expensive and your Dana 35 is cheap to replace. Put a WTB on Craigslist and local jeep clubs.
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Unread 04-20-2013, 08:21 AM   #11
Bong_Holyeo
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Quote:
Originally Posted by soonermatt View Post
To clarify on price: I sold my functional, 4.10 Dana 35 for $100 outright.

As you can see, dicking with axles gets expensive and your Dana 35 is cheap to replace. Put a WTB on Craigslist and local jeep clubs.
I agree a dana 35 is cheap to replace because no one wants them. I had to throw my dana 35 with 4.10 gears in the dumpster after my 8.8 swap because it sat on Craigslist for 6 weeks at 50$ with no interest at all.

However i will give you some advise that i did not listen to soon enough, DO NOT SPEND MONEY ON A DANA 35! 4.10 gear 8.8 out of a explorer has disk breaks and goes for 150$ around here
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Unread 04-20-2013, 08:21 AM   #12
bogleparsons
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Quote:
Originally Posted by soonermatt View Post
To clarify on price: I sold my functional, 4.10 Dana 35 for $100 outright.

Cost to install gears in new axle: $200
Cost of new gears: $200
Cost of used axle: $250
Cost of bearings, inner and out: $150
Oil: $15
And there's even more


As you can see, dicking with axles gets expensive and your Dana 35 is cheap to replace. Put a WTB on Craigslist and local jeep clubs.
They want $1600-1800 to do my regear at the local 4x4 shop
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Unread 04-20-2013, 10:42 AM   #13
Steve707
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Originally Posted by bogleparsons View Post
They want $1600-1800 to do my regear at the local 4x4 shop
Wow, i thought it was steep here at 2-300 per axle in labor. Does that include an air locker or something extra?
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Unread 04-20-2013, 02:13 PM   #14
TrentYJ
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Originally Posted by Steve707 View Post
Wow, i thought it was steep here at 2-300 per axle in labor. Does that include an air locker or something extra?
300 would be on the cheap for around here. Cheapest I could find was 600 per axle for labor only
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Unread 04-22-2013, 10:44 AM   #15
Flajeeper1
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$600 .... wow. I just had a Auburn electric locker installed and regeared an 8.8 to 4.10s for $250 at an axle shop. I agree to drill the hole and install a helocoil. There's no stress on the bolt when operating and it's cheap to do.
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