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Unread 10-23-2012, 04:24 PM   #1
2000wreckedwj
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Ring Gear Bolt Issues- HELP QUICK

I am in the process of changing out my gears in my WJ. I have the rear gear set out and have the old ring gear off. I went to install the new ring gear and the original bolts are too big for the new ring gear. The parts seem correct to what I ordered. Anyone have any ideas? Should I just get new bolts or send this gear set back and try another? I need advice ASAP Thanks

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Unread 10-23-2012, 04:57 PM   #2
Planetcat
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The ring gear bolts changed in I think 2001. In 1999-2001 or so, they were 3/8" bolts and then went to 7/16" bolts. Almost every part place I've run into doesn't know that there's a difference. At least this was the case with my rear Dana 44A. I'm not sure if this applied to the Dana 35 or not, but sounds like this is your problem. I would return them or you will need to tap/drill out your carrier and ring gear.
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Unread 10-23-2012, 05:27 PM   #3
2000wreckedwj
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thats odd. mine is a 2000. should I order them for a 2002 or 2003 then?
I searched and they are the same part numbers for all the years so I think I would end up getting the same thing I already have. How hard is it to drill and tap that metal? I figure it will be harder than normal metal. Any other options beside drilling them? can I just use the smaller bolts? would it work ok?
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Unread 10-23-2012, 07:02 PM   #4
StrokedWJ
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Where did you order the gear kit from? I'd call them and explain the situation and see what they can do to help. The ring gear with smaller bolt holes will need a carrier with smaller bolt holes as well as smaller ring gear bolts. It would probably be easier to return the gear set and get one with the larger bolt holes.

I may have some of the smaller ring gear bolts saved from my D35 regear a few years ago. Let me know if you want me to look for them...
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Unread 06-15-2013, 10:04 PM   #5
joctavioramos
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I have the same problem you had. How did you fix it? The original bolts are 7/16 and the new ring is for 3/8. Did you get a new part or did you use 3/8 bolts?... need help!!
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Unread 06-15-2013, 10:22 PM   #6
Planetcat
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Quote:
Originally Posted by joctavioramos View Post
I have the same problem you had. How did you fix it? The original bolts are 7/16 and the new ring is for 3/8. Did you get a new part or did you use 3/8 bolts?... need help!!
Use 3/8" bolts and sleeves in the diff holes. I had to do this on my rear dana 44A, and it's been fine.
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