1994 YJ Axle

When that happened to mine due to a so called 'Jeep' shop changing the yoke, I had a 'real' machine shop fix it properly. Mine needed all new bearings, seals and the proper shims. Ran about $500.00 for my Dana 44.

Repairing a part like that is best left to the professionals in my opinion.

If yours is the 35 C rear end, I would check with the local Jeep or 4x4 clubs because lots of folks upgrade from those so extras should be kicking around cheap. Or maybe they only upgrade after they break it?

Mike

Thanks Mike. It didn't look like something I'd want to dig into without the right tools. Do you think that much damage would have been done to the point where the existing axle can't be rebuilt?

D44, 8.25" from a Cherokee, or 9" from a Ford Explorer are commended upgrades. Dynatrac and other companies will build a new, beefed up upgrade for $$$$. Now is a good time to think about changing the axle ratio, but that would also involve changing the ring and pinion on the front. Going to a higher number axle ratio will let the engine work in its power band and could improve fuel economy.

Earle

Unfortunately there isn't any way to know for sure until it gets opened and inspected. In my case, the bearings just took up the damage so it was ok to repair.

Mike

It depends on what kind of noise, how loud, how soon you stopped driving it, and how you had it towed home. Dolly or on its own rear or front wheels? I had one in an old van start howling in the middle of Ohio on the Interstate, pulled into a truck stop, put Super Glue on the nut, torqued it to more or less the right torque, and it was good to go for years.

Your D35 has a crush sleeve that is used to set the bearing preload and allow proper tightness on the pinion nut at the same time. There is a proper procedure to follow, so it doesn't loosen up like yours did. Sometimes they recommend a new nut, if it is a lock nut, or at least chemical thread locker. I can tell you that Super Glue works great.

You may get by with new bearings, or even tightening the nut properly. On the other hand, you might have cooked the ring and pinion gears. Hard to tell without opening it up.

Earle

As soon as it started making the noise, I pulled off at the next exit, which was about 1/4 mile. In the parking lot I took off the rear drive shaft, tightened the pinion nut so the pinion was secure, and then drove home (less than one mile) with the front axle engaged. Looking at the guts of the differential, it all looks ok as far as I can tell. There are no chipped teeth, no metal chucks in the oil, etc. as far as the bearings, I can't tell.

What harm would it do if I just put it all back together and torqued the pinion nut to where it should be. I'll add a drop or two of super glue and see what happens.

Thoughts?

I would recommend Loc-Tite high strength thread locker or a similar product. Clean the threads with acetone to make sure the stuff sticks. You may want to invest in a new pinion nut. You have time to shop for the correct materials and parts, where I didn't. Did it make noise while you were driving it home? If it still made noise, then the damage is done, most probably to the ring and pinion. If it is quiet with the pinion tightened properly, then you may be lucky.

Earle

Well, maybe for a change I'll have some good luck!

It was nice & quiet on the way home. I'll post an update tomorrow afternoon.

Doug

......

What do you have to lose? I would advise you to get a new crush sleeve and nut. The crush sleeve is a one time use item and cheap. Replace the sleeve and nut, torque it to spec, then see what happens. From your description, I am assuming there was no collection of metal bits in the case when you opened it up so I would guess you have a better than even chance of salvaging it. As I said, what have you got to lose?

Ditto. God Bless America, Bill 0|||||||0 mailto: snipped-for-privacy@aol.com

You can get the service manual here to follow the procedure:

If the bearing lossend up because the nut was loose it would have messed up the gear contach between pinion and ring. I would expect them to be toast. If they are not, count your blessing but I would not hold my breath. One more thing if you were ever considering changing gear ratios, now would be the time to do it because if you have yo replace rear gear then you anly have to do the front too(you are have way there) One more tip, I have changed a LOT of pinion seals and never had any problems. The trick is to scribe a line on nut and pinion shaft BEFORE you remove nut and tighten it back to same place when you are done, no more, no less. If you change the yoke it gets a bit dicey because you are guess a bit because of minor yoke differences and the only way you can be 100% "sure" is to pull pig and check preload before and after with a inch pound wrench to match values.

----------------- TheSnoMan.com

Mine works just fine man, I don't need to know how to hack fix it, I had a machine shop do it right 'as I posted'.

Mike

So in other words you do not have a clue how to do it or how it was done of if it was done correctly. You only know it works. No surprize here given you "knowledge". BTW, my method is not a hack fix unlike most of your suggestions.

----------------- TheSnoMan.com

I don't particularly give a crap about your BS man, try reading the thread and posting to someone who might instead of posting to me.

Do you 'ever' read what you are posting to?

Just a hint, you are supposed to snip the part you are replying to and leave it 'in', not someone else's contribution and then post nonsense in the context.

Better yet, 'don't' snip 'anything' so then your foolishness 'might' make some sense.

Mike

hmmm. Maybe it is toast, maybe not. All I have to lose is about an hours worth of time putting everything back together. I suppose I would have had about the same experiance if I had done it myself as I would have with the shop I took it to in the first place.

Point is, I want the thing back on the road!

And at least now, its out enjoying the sun instead of being stuck in the garage! 20 feet closer to the road!

Wish me luck!

Good luck man!

Mike

excitment is building...

tightened the pinion, put the differential cover back on, filled it with oil, new battery.

roared to life after a two year break. started right up!

It sounds good in the driveway. no odd noises, seems good.

Tomorrow I'll fix the gas leak and take it around the block.

Thanks for all the advice, and the luck!

Doug

Cool, it's nice to get lucky. I was on mine also, it's doing fine 7000 miles later, but I knew the bearing had damage, I could feel it. While mine was open, I had them put all new bearings inside because they were vintage 1986 with 'some' play and it's a nice Dana 44.

Mike