Dana 35 access cover?

[CopyKat]

I mentioned this to Joel a couple of years ago and have been sitting on the idea.

I wanted to do this to TRS-2 later this year and add the 44 knuckle swap.

Since you guys are doing this, I'll go ahead and tell you my ideas......

I had two ideas on how to do this:

1 - Make a thick ring (like say 3/4 or 1-inch) that has two sets of holes in it. One set that would allow bolts to recess in to the ring and hold the ring and diff housing to the beam sandwiching the beam between them. The second set of holes would be tapped to allow a cover to bolt to the ring.

2- I like this idea better, a thick ring like above, but it would be welded to the beam to strengthen the beam from the section being cut out. Again, two sets of holes, but the holes for the diff housing would go through so that the original bolts would be bolting the diff housing to the beam, but be recessed in to the ring. Again, a second set of holes would be tapped to allow the cover to bolt on.

I don't like the idea of a cover that uses the same bolts to hold the diff housing to the beam.

I think the ring should add some strength back in to the beam since your cutting a section out.

Sharpertouch, I think you should take the design a step further. I wouldn't want to worry about the diff housing coming loose when I take the cover off. I would want to be able to take the cover off and clean all the crap out without worrying about the sealant holding the diff housing to the beam.


I tried the whole pump idea to get the diff fluid out from the fill hole. This idea sucks. It took forever and is a pain in the ass. I doubt I even got all the fluid out. Have you ever looked at the slime that get's in your diff from playing in muddy water? Yes, I have vent hoses but it still gets in some how.

That was long ago Jim.

Ya the thought has crossed my mind from time to time. I was thinking of doing it with the new beams I built but after seeing how easy it is to bend them in stock form. I voted against the idea. If I was to do it for a street truck i would go the #2 route Jim mentioned.

For simplicity I did the same as sasquatch and drilled/tapped a hole for a plug on the bottom of the housing. I don't have an e-clip, because I have a lock rite, so it's a moot issue for me.

 

[sharpertouch]

thanks for all the feed back everyone!

jim - i also had a similar idea of keeping the diff attached to the housing using seperate bolts. however... there is still a vertical bolt that holds the diff to the axle housing on the rear side... also for whatever its worth the gasket sealer and the axle itself help hold it on aswell. in the past ive always had to pry the diff free after disassembling everything from it (only gasket sealer holding it together.) also im hoping the 3/8 ring will suffice for ridgity.

 

[sharpertouch]

access cover still together and not leaking. tightened all the bolts after a couple trips to work (60 miles round trip)

 

[Mechanickid]

sounds good man! were you featured in Peterson's 4x4 magazine on the readers rides section?

 

[Ranger44]

Well crap. I must have totally missed this post. This is a pretty cool idea.

Not sure if I will ever attempt this. Seems like it would possibly weaken the beam, and there'd always be that worry in the back of my head.....

I think tapping a drain plug would be a little better for me.

 

[sharpertouch]

so a year later and shes held up just fine. no leaking. no bending.
drove the truck from NJ to TN went wheeling at Windrock. Had all four 35's spinning and hoping up a steep wash out with my winch assisting. then drove to NC then back to NJ. i blew my tcase and broke my trans cross member. still no problems with the axle.

 

[RacinNdrummin]

That is a cool idea, nice application of it.

 

[whitetrash96]

Did you re-use your stock diff bolts or did you have to get longer ones?

 

[sharpertouch]

whitetrash96 - i got some longer bolts.

Mechanickid - nah it wasnt me. however i sure wouldnt mind being featured.

 

[twoll86]

was just think about doing this yesterday lol but i would do it similer to what Allan said only i would start with 2 spare beam cut the section out for the opening and adding/welding a 1/2in plate on the beam drilling and taping the holes in the 1/2 plate and using that with studs to hold in the diff then use the 2nd beam to make my diff cover.

should make pretty strong and keep the diff in place

what ya'll think of that idea?

 

[sharpertouch]

just an update- its almost three years to the day now! no breakage twisting or anything other than a small tiny leak. would have not leaked any had i used a sealer on the gasket...
hope all is well. happy holidays

 

[alwaysFlOoReD]

Good job. How many times have you taken the cover off? Is there anything you would change in your design?

Richard

 

[sbsrlewis]

Thats good to hear. I have wondered how the beam would hold up. I would like to see if an Ox locker could be made to work on the ttb d35. One these days I might give it a try.

Steve

 

[AllanD]

the removeable cover would have ONE beneficial effect....

the ability to access the E-clip that retains the passenger side axle shaft.

That along might justify doing it.

Because the various spring based c-clip elimination schemes are all
questionable IMO.

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[Hahnsb2]

Because the various spring based c-clip elimination schemes are all
questionable IMO.

AD

Because it works?