Side/Spider Gears chewed up

VortecJeep

VortecJeep

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Joined
Aug 24, 2005
Location
Concord, NC
96 ZJ on 33s, stock drivetrain:
Bad metal on metal noise when coasting, it goes away when I press the gas and put it under load. Just started yesterday. This morning I pulled the rear diff cover and the side gears/spider gears are chewed up on the ends of the teeth. So far it doesn't look like the ring and pinion are damaged, but I can't rotate it to see it all because I left my jack at someone's house.

If it is just the side gears and spider gears, can those be replaced without going thru setting up gears? I don't want to put much money into this Dana 35.
 
Yes they can be replaced without gear set up. Axle shafts have to slid out of the way just a bit. There is a small bolt with a 1/4" 12 point head. Remove it and the center pin should be able to come out. Then remove the spider/side gears. Your thrust washers may meed replacing also, I can't remember if they come with a gear kit or not.
 
i spider gear set comes with new side gears, spider gears,new thrustwashers, new center pin, and set screw. We can sell you a new set for $95 shipped. replace as said pull shafts and pin and roll out spiders.
 
buckshot500 said:
Might be a good time to look at lunch boxes. Been hearing good things about Aussie lockers.
Click to expand...
I don't want to put that much money into a Dana 35. I am planning my TJ build, at which time I'll sell the ZJ. I am putting an Aussie in the HP44 that I am putting in the TJ.

CPerry, I am sending you a PM.
 
If you need a set of spiders I'm sure I have a few around. I can give you a hand with them if needed.
 
You wont have any trouble as long as you get the EXACT wrench for that little bolt. I have one by the way that you can borrow. Get some blue gloves, Rightstuff gasket stuff, a 90 angle air tool / roloc pads to remove the old gasket and youre good to go. I will make you up a goodie box and you can pick it up when its time. Its easier to jack up the jeep, set it on stands and lower the rear axle (remove the tires).
Easy-peezy-lemon-squeezy :gay:
 
In case anyone needs to know how to replace Dana 35 side gears and spider gears

Here's a pic of the chewed up Dana 35 spider gears and side gears:
ai303.photobucket.com_albums_nn152_VortecJeep_ZJ_ZJspidergears2.jpg

I contacted CPerry here on NC4x4 and got the kit with side gears, spider gears, cross shaft and bolt.
I jacked up the rear end and put it on jackstands and chocked the front wheel with the rock I always keep next to the driveway just for that very reason:
ai303.photobucket.com_albums_nn152_VortecJeep_ZJ_ZJ.jpg

To remove the c-clips, I removed the wheels and brakes to slide the axleshaft in and out. With the calipers on, it would not push in far enough to get the c-clip out.
ai303.photobucket.com_albums_nn152_VortecJeep_ZJ_ZJbrakesoffaxleout.jpg

Installing the side gears was a breeze. The spider gears took a couple of tries because you "walk" one in, and then "walk" the other in. But you have to walk the first one in farther than needed because the first one will walk outward as the second one walks inward. I also installed new c-clips and the old ones will be my spares to go along with my spare shafts.
 
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