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.
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.
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?
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.
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
$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.