dana 35 leaking

[twb4525]

the d35 is leaking gear oil in my 1993 ranger. although it is not bad yet, eventually it will be addressed. just wondering if you guys have any tips for removing the front diff.?

I plan on doing the following while everything is apart (what are good quality replacements):
1. c-clip eliminator
2. replacing the inner passenger u-joint (both outer axle u-joints have already been replaced with grease-able joints in years past)
3. replacing axle seals

is there a gasket available for the front diff or just use rtv silicone?

the real only "challenge" I see is the driver side pinch bolt...

(on a side note, I will be swapping to a bw1354m too!!)

thanks,
-tom

 

[adsm08]

just wondering if you guys have any tips for removing the front diff.?

Set aside a 3 day weekend.

Have good heat.

Torch.

Hammer.

Torch+hammer= awesome.



Oh, don't use a ball-joint press or C-clamp on the u-joints. It will warp and ruin the shafts. The proper way is to lay the ears across a vice and knock them out by tapping at the weld of the other shaft.

 

[4x4junkie]

tapping at the weld of the other shaft.

I've always used a shop press when doing u-joints on mine. If the u-joint is being stubborn (rust, etc.), giving it a good whack with a hammer while under pressure will almost invariably pop it loose (often with a good bang lol). I don't see why this wouldn't work while using something like a ball joint press also.

For the pinch bolt, if you can't get it out past the radius arm, grind it's head into a "D" shape, which will then let you wiggle it out past the arm (resist the temptation to notch the radius arm, this will cause a stress riser and possible radius arm failure at a later date), then reinsert the bolt from below rather than from above.

Diff is sealed with RTV (factory).