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Newbie-broken axle help!!


 
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olhogrider
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Joined: 22 Nov 2005

PostPosted: Wed Dec 07, 2005 11:19 am    Post subject: Newbie-broken axle help!! Reply with quote

My '98 TJ has a broken axle. I know it is a Dana 35. I bought a used one but it turns out mine is not a C, as in "c" clip. Also it appears to have a limited slip. There are plates that resemble a motorcycle clutch on the shaft. How do I get the broken stub and gear out? No c-clip to remove. This is on the driver's side. This is my first tim in a differential.

Please Help! Thanks.

Dan
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ehirner
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Joined: 01 Jan 2004
Location: Eastern PA

PostPosted: Wed Dec 07, 2005 2:44 pm    Post subject: Reply with quote

The Dana 35 in a 98 TJ is a C-clip rear. It's possible you may have a D44.
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olhogrider
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Joined: 22 Nov 2005

PostPosted: Wed Dec 07, 2005 5:25 pm    Post subject: Reply with quote

Nope. Rounder cover, rubber fill plug, 3.07:1 gears. Doesnt sound like a 44 to me. OK so if it was, or something has been changed by a p.o. how do I get the gear off the axle? How do you pull the axle on a non-c-clip axle?
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olhogrider
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Joined: 22 Nov 2005

PostPosted: Wed Dec 07, 2005 6:12 pm    Post subject: Reply with quote

While your reply didn't really answer my question, it did inspire me to go have another look. At night, in the rain with a flashlight I saw the clip! I still can't get the clip off. The gear doesn't want to slide on the axle, but in the morning I might be able to get it. Thanks
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ehirner
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Location: Eastern PA

PostPosted: Wed Dec 07, 2005 7:53 pm    Post subject: Reply with quote

For D35 and Ford 8.8.....

Remove rear wheels and brake drum (or discs).
Remove diff cover.
Remove crosspin retainer bolt.
Remove crosspin (be careful not to have the side gears fall out).
Push in on axle shaft.
Remove C-clip (it may fall off the shaft once it's pushed in)
Remove shaft from housing.

Installation is reverse. I didn't include all the details but this will get you through it.
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olhogrider
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Joined: 22 Nov 2005

PostPosted: Wed Dec 07, 2005 8:57 pm    Post subject: Reply with quote

Thanks. I got it out. The big problem, once I found the c-clips, was the axle shaft itself had broken inside the gear. That made it impossible to move the gear and remove the axle. By pulling the opposite side axle and gear, I had room to pull the broken bits out. I'll put it back together in the morning.

Again , thanks for the help.
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olhogrider
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Joined: 22 Nov 2005

PostPosted: Fri Dec 09, 2005 8:38 am    Post subject: More help, PLEASE Reply with quote

I put the gears onto the axles but I can't get enough room to put the gears in that go on the short shaft. What am I doing wrong?
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ehirner
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PostPosted: Sat Dec 10, 2005 6:37 am    Post subject: Reply with quote

This may not make sense in text, but you position them in the "window", then rotate the spider and side gears into position. Install the crosspin once the gears are in position.
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