Dana 35 experts please.

[Blackdog]

I have a 97 Ranger 4X4. I pulled the Dana 28, and replaced it with a Dana 35. The Dana 35 has new 4:88 gears, bearings and seals. I'm using the Dana 35 axles that were with the differential.

When I was assembling the passenger side hub I found I could not install the spacer and "C" clip on the axle end because the axle didn't stick out far enough. I tried prying the axle out a little but it was out all the way.

Why won't the axle protrude out far enough for the spacer and clip? The inside end of the axle is held in by another "C" clip in the diff. I'm thinking that the gear installer moved the gear assembly while shimming it, the 4:88 gear is much thicker than the original 3:73.

Any ideas?

 

[Sasquatch_Ryda]

The drivers side axle is not held in a with a c clip in the diff, just the passenger side is.

I've run into this problem myself a couple times, and i've found that the wrong spindle seal will cause this problem. There is also the dust seal that is on the axle shaft itself that rides on the spindle, make sure that there isn't 2 plastic washer stuck behind there, only 1.

 

[Blackdog]

The drivers side axle is not held in a with a c clip in the diff, just the passenger side is.

I've run into this problem myself a couple times, and i've found that the wrong spindle seal will cause this problem. There is also the dust seal that is on the axle shaft itself that rides on the spindle, make sure that there isn't 2 plastic washer stuck behind there, only 1.

I meant pass side, thanks.

It seems to me that the pass side axle will have about 1/4" of in/out play, right? Mine has no play at all. I'll check that axle dust seal tomorrow (right after I shorten the drive shaft).

 

[4x4junkie]

Yeah, sounds like you might have a leftover shim or seal part stuck in the spindle still.

The shaft should have no more than about 1-2mm of in-out play with the c-clip & washer(s) installed.

 

[Blackdog]

Yeah, sounds like you might have a leftover shim or seal part stuck in the spindle still.

The shaft should have no more than about 1-2mm of in-out play with the c-clip & washer(s) installed.

Got up this morning and attacked the problem with a fresh mind. I found a plastic shim that seemed out of place. I took it out and the problem is fixed. Thanks