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Unread 03-11-2009, 10:27 AM   #1
95wrangler4life
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1995 YJ Wrangler 
 
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Dana 35 Pinion Seal replacement question

Can someone give me the quick run down on replacing my pinion seal on the 35? I still drive mine on the road so it needs done right. My buddy said when he did his (CJ) that he just pulled the yoke, pulled the old seal, seated the new seal and reinstalled the yoke and never had to mess with the gears! But wasnt sure this would be good for driving on the road, since his CJ is trailered!


Thanks

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Build thread: http://www.jeepforum.com/forum/f22/b...-dirty-894483/
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Unread 03-11-2009, 10:31 AM   #2
obsessedjeeper
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sounds like all i did to mine when i replaced it. its pretty straightforward
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Unread 03-11-2009, 12:59 PM   #3
cmsurfer
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Do yourself a favor a get a seal puller. I replaced the pinion seal on my D35 last year and went through hell trying to get the old one out. I ran to Napa, got a seal puller, and had it out in about 10 seconds.
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Unread 03-11-2009, 01:04 PM   #4
lonestar_yj
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just changed mine last week, about a 30 min. job. pulled the drive shaft off. used a 1/2 inch impact gun to take the nut off and used a screw driver and a little pry bar to pop the seal out, taped the new one in and used the impact gun to put the nut back on
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Unread 03-11-2009, 01:10 PM   #5
Tulsachokehold
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Quote:
Originally Posted by 95wrangler4life View Post
Can someone give me the quick run down on replacing my pinion seal on the 35? I still drive mine on the road so it needs done right. My buddy said when he did his (CJ) that he just pulled the yoke, pulled the old seal, seated the new seal and reinstalled the yoke and never had to mess with the gears! But wasnt sure this would be good for driving on the road, since his CJ is trailered!


Thanks

that is EXACTLY how it is done. You need to be sure you drive the seal in straight. if it s crooked at all you will be replacing it again in no time.
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Unread 03-11-2009, 02:35 PM   #6
95wrangler4life
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thanks guys, appriciate it, he just wanted to be sure we didnt have to worry bout messin with gears or anything!
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Build thread: http://www.jeepforum.com/forum/f22/b...-dirty-894483/
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Unread 05-15-2009, 09:57 AM   #7
Nerv
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I've been told not to use an impact gun, could possibly damage the pinion.

Follow these simple steps
1. Mark the driveshaft to the yoke before removing the driveshaft. Careful not to release the needle bearings in the u-joint.
2. Mark the pinion, nut and yoke with a straight line for re-installation later.
3. Remove the pinion nut.
4. Pull seal out, lube the new seal before installing it
5. Reinstall the pinion nut and tighten to the same location as before, then turn 1/8 of a turn more, this will preload the bearings in the pinion shaft. [Use red locktite if re-using same nut]
6. Reinstall yoke and driveshaft to same position as before. [Use some sealant on the inside of the yoke to keep oil from seaping through the splines.

That's it!
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Unread 05-15-2009, 11:10 AM   #8
jaywiz1977
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if it's got a leak thats a good time to upgrade to a better axle!thats what i told my wife would cure mine from putting that spot on the drive....that d35 has never leaked on the drive since!
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Unread 07-04-2010, 05:42 PM   #9
mmarmouz
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well, i have to change my pinion seal soon, do i have to remove the differential cover and flush the old fluid before doing that ? or the seal can be changed with the oil in the differential ?

i have a dana 35 on a tj
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Unread 07-04-2010, 07:49 PM   #10
jdubsjeep
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no need to drain, unless the oil is milky from water or has a lot of miles on it. I always put a catch pan under my work so if I loose some oil it won't leave a mess.
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Unread 07-04-2010, 09:59 PM   #11
mmarmouz
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thank you, well now i guess i have work to do
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Unread 09-15-2010, 04:34 PM   #12
spankinkopita
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Know this thread is old

I just replaced the seal on my 35, when I did it I later discovered a part in the box I did not remove during the breakdown but looks like a collapsible pinion spacer, should I have put that in?
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Unread 09-15-2010, 05:25 PM   #13
95wrangler4life
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that is the crush sleeve, which is the reason behind not using a impact gun on the nut when putting it back on and not over torquing.
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Build thread: http://www.jeepforum.com/forum/f22/b...-dirty-894483/
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Unread 09-15-2010, 05:40 PM   #14
spankinkopita
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Aw Shucks

Looks like I'll be awaiting a new seal so I can pull it and reinstall. Does it go on between the seal and shaft or the pinion and seal?
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Unread 09-15-2010, 07:18 PM   #15
95wrangler4life
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hopfully someone with more knowledge will chime in, when i did mine, i did not replace the crush sleeve so i have no clue, and it worked fine for a while.
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Build thread: http://www.jeepforum.com/forum/f22/b...-dirty-894483/
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