post #1 of Old 10-03-2012, 04:23 PM Thread Starter
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2005 TJ Wrangler 
Join Date: Oct 2011
Posts: 5
Dana 35 differential gear a little chewed up (some metal shavings inside).

So I changed my differential fluid again after noticing a leak from what appeared to be the pinion seal failing. I noticed some metal shavings inside the differential and also that the oil seemed silvery. After I took off the differential cover I noticed one of the smaller gears (one of the four grouped together next to the large one, see picture), seemed to have some small chunks missing; it also has some play when I moved it. There doesn't seem to be any kind of performance issues as of yet though. I cleaned it out with brake cleaner and got all the metal shavings out, and replaced the oil and sealed her up. What do you think, is it necessary to replace that gear?

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post #2 of Old 10-03-2012, 05:37 PM
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1992 XJ Cherokee 
Join Date: Oct 2007
Location: Rosamond, CA
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Originally Posted by srm1982 View Post
What do you think, is it necessary to replace that gear?
Yep. And all the other gears and bearings, too. Keep in mind that I go so far out into the Mojave Desert that if I broke down, they would never find my body. So I tend to go a little overboard on repairs and maintenance. If you are just thrashing around in the back yard, you might decide you can live with the inconvenience of a breakdown.

But if that were mine? Oh yeah, I'd rebuild the entire axle assembly.

The road goes on forever, the party never ends....
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post #3 of Old 10-03-2012, 07:00 PM
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1986 CJ7 
Join Date: Oct 2009
Location: worcester
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Time for a Dana 44.

Rubicon Rich ,05 TJ Rubicon:
86 CJ7 258,T18,Scout Dana300,twin sticks,Dana44's,4W Disc, locked,35's,YORK OBA,Warn 8274,fullcage.
51 M100 1/4 ton Jeep trailer
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post #4 of Old 10-09-2012, 03:56 AM Thread Starter
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2005 TJ Wrangler 
Join Date: Oct 2011
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Thanks for the advice. I am looking into replacing the spider gears. When I replaced the pinion seal I checked out the bearings and they seemed fine. I've spent the last couple of hours looking into the different options with differentials and gearing ratios... but it seems for the time being a 45 minute gear replacement would set my mind at ease up in the mountains looking for Bambi's dad.
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