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Unread 04-02-2010, 03:26 AM   #1
navis
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1994 YJ Wrangler 
 
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Grinding coming from dana35, overheating

Sorry if this post is a little sloppy, it is 2am and i have been up for almost 24hrs. For a while the rear dana 35 on my jeep has been leaking. so tonight i took the cover off, wire wheeled the gasket surface, cleaned the inside of the dif with parts wash, applied gasket maker, replaced cover and filled with oil. about 2km down the road i heard a loud bang and immediately pulled over. It now makes an extreme grinding noise to the point where it was almost unbearable to push it 50 feet down the road. The pinion was too hot to touch, and even the rear u-joint was steaming. I pulled the cover again and inspected the inside. form what i could see there was no visable damage to any of the gears. There are gale force winds, pouring rain, and nearly freezing temperatures right now, combined with working in the dark i decided to wait until morning. Where to start? :s

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Unread 04-02-2010, 05:27 AM   #2
Louie4
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I would pull the rear drive shaft and put the rear axle up on jackstands and try to turn the pinion by hand. Pull the cover off and again and maybe pull the carrier. That will tell you a lot. Sounds like the pinion bearings might be toast causing the gears to grind and not mesh well.
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Unread 04-02-2010, 08:19 AM   #3
nj95yj
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yea pull the cover and check things out
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Unread 04-02-2010, 08:36 AM   #4
Tshark299
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Quote:
Originally Posted by navis View Post
... I pulled the cover again and inspected the inside. form what i could see there was no visable damage to any of the gears. ...
Quote:
Originally Posted by nj95yj View Post
yea pull the cover and check things out
Nice
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Unread 04-02-2010, 08:52 AM   #5
planedog
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If it wasn't grinding or getting hot before I would suspect some of the wire or debris from cleaning the gasket surface got into the differential. The ring will throw the gear oil and anything in it into the top of the pinion bearings where it will stay until it is ground small enough to come out the bottom of the bearings.

Sound like it may be time to get an 8.8!
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Unread 04-03-2010, 12:43 AM   #6
navis
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I didn't get a chance to get too much done today. I loaded the jeep on a flatdeck and brought it home to the shop. It's all up on jackstands now with the tires off and the driveshaft out. I removed the diff cover and removed the main pinion nut securing the yoke. Using a bearing puller and torquing on it with a 3/8 ratchet and 3' handle extension the yoke will still not come off. I had it off a few months ago when the driveshaft blew. Why isn't it comming off??? The puller is actully cutting metal out of the center of the pinion shaft, that's how hard it is pulling.

I am lost and up for ideas. How reasonable is it to rebuild the diff having never done it before? Is it something an average person willing to listen/learn can do in an afternoon?
Thanks again!
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