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Unread 03-27-2015, 06:56 PM   #1
yj4me
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yj axle help

Recently my d35c rear axle with ARB and warn manual hubs decided to blow up after more than 15 years of use. Skipping the part about me needing a new rear axle, I'm having trouble removing the axle shafts. I have watched several video's and read many of the posts here, but I haven't found any that deal with ARB AND Warn rear hubs. The question is, do I still have C clips to remove? I can't see them or find them or get access to them. See pictures..(parts in diff cover fell out upon removal.)

20150326_163654.jpg

20150326_163709.jpg

20150327_173548.jpg  

Last edited by yj4me; 03-27-2015 at 07:08 PM.. Reason: added picture
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Unread 03-27-2015, 07:39 PM   #2
Steve707
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Wouldn't the hubs need to come off so the shafts can come out?
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Unread 03-27-2015, 10:21 PM   #3
yj4me
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yes, i have removed tires, hubs, breaks, and all the hub pieces. When I pull the axle shaft on either side it moves maybe an inch or so then stops at the edge of the gear. I'm wondering if the C clips are behind the gear but also can't get out that last pin with the smaller spider gear. I'm thinking things are wedged in due to the extent of the damage to the ARB and ring gears etc..

Last edited by yj4me; 03-27-2015 at 10:21 PM.. Reason: changed wording
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Unread 03-27-2015, 10:27 PM   #4
flipit
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I'm just winging it here, but is your axle shaft running into an outer seal? I haven't worked on a 35, but, you should be able to see what your shaft is hanging up on...I would think
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Unread 03-27-2015, 10:37 PM   #5
yj4me
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I don't think it is, here is a picture of the axle shaft
20150327_213557.jpg  

Last edited by yj4me; 03-27-2015 at 10:40 PM.. Reason: add image
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Unread 03-28-2015, 01:48 AM   #6
ttop191
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I dont have experience with the guts of a dana 35 but i know on the 3 ford 7.5 axles ive done gears on in order to get the c-clips push your axle shafts in towards the center of the diff. If they are there you'll see them then.

edit: After taking another look at your pics. Specifically the last one in the first post. Those are definitely not c clip axle shafts. It's possible some debris from the ARB scored your axle shaft and it's catching on the inner race of a bearing or on a seal.

2nd edit: also welcome to the forum and I'm curious to know your tire setup since you lasted so long with a locked d35
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Unread 03-28-2015, 05:34 AM   #7
pete1991YJ
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Nope, no c-clips here. The end of your axle shaft is warped/distorted enough to make removal difficult, if I look closely at the pics... if it were mine, I would be using the torch to cut off the side gears, then slide the shaft out. Likely the only part that can be saved is the axle housing.
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Unread 03-28-2015, 06:51 AM   #8
yj4me
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Thank you everyone for all the replies, and thanks for the welcome to the forum.

33" tires on 4:56 gears, 4:1 xfer-case reduction. When the drive shaft was made shorter to fit the 4:1 and lifts, the axle was also "very slightly" turned to help with the angle of the drive shaft etc...
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Unread 03-28-2015, 08:45 AM   #9
Jeepsr4me
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Just snatch the axles out... If there is any burs on the end inside the diff, file those off before snatching..

I have a slide hammer to help get things to moving that dont want to move..
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Unread 03-28-2015, 11:33 AM   #10
Joe Dillard
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By the looks of things, pretty much everything is toast

Are there reasons you're putting the effort into disassembly?

A friend of mine is who designed that kit many years ago in an effort to satisfy a few folks who felt the need to keep the D35 but wanted some sort of upgrades.
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Unread 03-28-2015, 12:14 PM   #11
yj4me
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When I started, I was just trying to assess why I broke down. At this point, rather than buy tools needed to get the gears / Axle shafts out, I'm more likely to replace the d35 completely. Contemplating putting it back together so its at least mobile vs. jack stands to move between garage and driveway until I'm able to put together a replacement axle with ARB etc... Always a tough debate when you start dealing with axles. I suspect the front stock axles can't be far from destruction also. Last summer while fixing an air leak on my front ARB, I learned they don't even make the O-rings for my ARB's any more, or so I was told. I suppose its time to make some hard decisions. 8.8, d40, d60, stick with 4:56 or move to 4:88 and larger tires 35" etc...

I suppose that's why i tinker with dis-assembly, its something i can do now while avoiding expensive decisions.
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