Post by greenbean on Sept 10, 2006 20:36:16 GMT -5
All,
This is a side thread off my main buildup, and is really for anybody who hasn't popped a diff cover and pulled their axle out. This will deal strictly with the TJ Dana 35c. I cannot comment on any other axles as this is the only one I've worked on! ;D
Next let me say safety is paramount, Use jackstands if you jack up your jeep, especially if you are the only one home!! Wear eye protection and gloves,...(Your eyes and knucles will thank you!!! ;D)
Okay first you need to pull the wheel on the axle side your going to work on, so you jack that side up,(once you have loosened the lugs a little) and put a stand under the axle tube near the wheel.
Place a catch pan under the rear end as you will be draining all the oil out. Take all the Diff cover bolts out and set them aside in a safe place, Air tools are a plus here!!!
Here is a pic of the Dana 35c on my jeep ready to have the bolts removed;
Next take a small Flat head screwdriver or similar tool and work the cover off the housing from one side, It should be stuck on there with RTV or similar sealant. Br prepared to catch the cover as it may suddenly come loose, so if you don't catch it you will be cleaning a lot of rear end oil off of it!
Here is a pic with the cover off and the oil nearly drained;
Once the oil is drained rotate the carrier,(It should turn freely with your hand) till you see a small star head bold on ONE side, don't worry it's obvious. Remove the bolt and set it in your differential cover for later.
Here is a picture of said bolt;
Once the bolt is out, rotate the carrier till you can see the cross shaft, It looks like a round cylinder tha has little gears on each end of it, from the opposite side of the carrier that you removed the bolt, push the shaft out, It should come out easily.
Next walk around to the side where the tire mounts to the hub and push the center of the axle in till it stops.
This will expose the infamous "C-clip" so you can just grab it and pull it off, or in my case it just fell off without me touching it!
Here is a picture of the c-clip laying on the bottom edge of the carrier,....
Once that is done walk around to the side you just pushed in on, and you can now pull the axle all the way out!(Carefully)
You may find as you rotate the wheel or axle with the cross-shaft out the spider gears will come out also. If they come out set them with the stuff in the Diff cover, be careful there are two little shims stuck to the gear with oil!
Here is a picture with all the removed parts.
To put the spider gears back in, you will have to start them on opposite side s of the carrier, then roate the axle till theythey line up for insertion of the cross shaft.
Re-assembly is opposite of disassembly .
Before you put the Diff cover back on, scrape all the old gasket material off so you have a nice clean surface for the rtv gasket YOU make. Make a bead of RTV all around the edge of the cover and around the bolt holes. Put bolts back in and tighten the cover back down. Once that is done, pull the plug on the Diff cover and re-fill the rearend with the appropriate Rear-end oil till you can just see the oil coming out of the hole.
Once its filled, put your wheel back on, tighten the lugs and remove your jack and jackstands and drive away! Note keep an eye on your RTV seal to make sure you don't have any leaks. Thats it! Easy, right?
Will
This is a side thread off my main buildup, and is really for anybody who hasn't popped a diff cover and pulled their axle out. This will deal strictly with the TJ Dana 35c. I cannot comment on any other axles as this is the only one I've worked on! ;D
Next let me say safety is paramount, Use jackstands if you jack up your jeep, especially if you are the only one home!! Wear eye protection and gloves,...(Your eyes and knucles will thank you!!! ;D)
Okay first you need to pull the wheel on the axle side your going to work on, so you jack that side up,(once you have loosened the lugs a little) and put a stand under the axle tube near the wheel.
Place a catch pan under the rear end as you will be draining all the oil out. Take all the Diff cover bolts out and set them aside in a safe place, Air tools are a plus here!!!
Here is a pic of the Dana 35c on my jeep ready to have the bolts removed;
Next take a small Flat head screwdriver or similar tool and work the cover off the housing from one side, It should be stuck on there with RTV or similar sealant. Br prepared to catch the cover as it may suddenly come loose, so if you don't catch it you will be cleaning a lot of rear end oil off of it!
Here is a pic with the cover off and the oil nearly drained;
Once the oil is drained rotate the carrier,(It should turn freely with your hand) till you see a small star head bold on ONE side, don't worry it's obvious. Remove the bolt and set it in your differential cover for later.
Here is a picture of said bolt;
Once the bolt is out, rotate the carrier till you can see the cross shaft, It looks like a round cylinder tha has little gears on each end of it, from the opposite side of the carrier that you removed the bolt, push the shaft out, It should come out easily.
Next walk around to the side where the tire mounts to the hub and push the center of the axle in till it stops.
This will expose the infamous "C-clip" so you can just grab it and pull it off, or in my case it just fell off without me touching it!
Here is a picture of the c-clip laying on the bottom edge of the carrier,....
Once that is done walk around to the side you just pushed in on, and you can now pull the axle all the way out!(Carefully)
You may find as you rotate the wheel or axle with the cross-shaft out the spider gears will come out also. If they come out set them with the stuff in the Diff cover, be careful there are two little shims stuck to the gear with oil!
Here is a picture with all the removed parts.
To put the spider gears back in, you will have to start them on opposite side s of the carrier, then roate the axle till theythey line up for insertion of the cross shaft.
Re-assembly is opposite of disassembly .
Before you put the Diff cover back on, scrape all the old gasket material off so you have a nice clean surface for the rtv gasket YOU make. Make a bead of RTV all around the edge of the cover and around the bolt holes. Put bolts back in and tighten the cover back down. Once that is done, pull the plug on the Diff cover and re-fill the rearend with the appropriate Rear-end oil till you can just see the oil coming out of the hole.
Once its filled, put your wheel back on, tighten the lugs and remove your jack and jackstands and drive away! Note keep an eye on your RTV seal to make sure you don't have any leaks. Thats it! Easy, right?
Will
