So, after 5 years running my built D35 (ARB, 4.56 gears) on borrowed time with all the extra weight and horsepower in the YJ it conveniently blew while my wife was driving it to the grocery store - "What did you do to it honey?".
The cross shaft sheared in the spider gears and made a solid axle out of it. Can't figure how to get it apart unless I start cutting the ARB case apart with the torch.
I scored a Ford 8.8 from an explorer with disc brakes and a Solid cover for $300 on the local Craig's list so here we go.
I have stripped the 8.8 (anyone looking for a Trac-Loc carrier with 3.73 ring and pinion?).
I have ordered spring perches, u-bolt kit, 4.56 gear set, master rebuild kit, e-brake hardware kit, and another ARB for the 8.8. I shopped around and should have about $1600 into the project unless I can sell some of the used parts that I don't need.
Don't know how I would get the rest of the center shaft out of there since it is bent and none of the holes are lined up anymore. Thought I could salvage the shafts for someone who needs spares or the 4.56 gear set but I might just have to sell the whole thing to the local scrap guy.
I know, but when I wanted to regear the Jeep originally to 4.56 a guy at a shop in PA sold me the D35 with the ARB and 4.56 gears installed for $400 plus he gave me $100 trade in on my old D35 so I jumped on it. It did last me 5 years but I always knew it was the weak link in the jeep. Kinda surprised it was the ARB that detonated and not something else though.
I am really wanting to put a selectable locker in when I finish school and get a real job. I drive my YJ around town quite a bit and it would be nice to have the open diff around town. Of course I've been riding on a lunchbox locker in the rear for years. I guess I'm just getting old.
Once you opened it up - what did you observe as far as the main crosspin retainer goes?
Was it still fully screwed in?
If not, was it backed out?
Is there evidence of locktite on the threads?
Prior to it going boom-boom, did it sometimes have troubles unlocking?
There were no warning signs from the ARB. The retainer appeared to be undisturbed and I thought it was backing out normally but turned out it was sheared as only about 1/3rd of it came out and the rest remained in the case. 7 or 8 of the case end screws had sheared due to the twisting of the case but the heads of those were rattling around in the bottom when I opened it up. About 1" of the main center shaft sheared off and came out of the case. The rest appears to be bent since the end with the retaining screw is still where it belongs and you can clearly see in the pics that the spider gears are not where they are supposed to be. A tech at ARB told me that a dead blow hammer and a big punch on the end of the main center shaft would probably work to shear the remaining retaining screw since it is small and brittle but I don't know that the shaft has anywhere to go since everything is twisted up inside. Haven't had time to fool with that yet.