DANA 35 Nitro 4.88 Gear install help.

[nooch450]

First let me tell you that the Nitro Instructions suck...

1. What should my backlash actually be Nitro said .006-.010 in install book???

2. The nitro kit came with pinion shims that need to go behind the bearing race (nitro install instructions do not tell you this)... This is bullshit because I pressed the new race in and tapping it out must destort it so i had to buy a new one for final install....

3. The kit came with no carrier shims, the only shims that came out of the diff were on the outside of the carrier bearings between the outer race and housing.(thicker than .120) I put them back in the same way they came out but i cant get the pattern to be sufficient with these shims.
I replaced the pinion shims (the one that goes behind the bearing race) to get the backlash into spec (.006-.010) but my pattern is too deep...

As of now I have no way of shimming my carrier so I ordered 2 differnt shim kits for the carrier. One with the thick looking washers and the other with the thin looking washers. (im not too happy with nitro)

Why does my TTB have external shims on the carrier bearings but the (http://www.therangerstation.com/tech_library/pdf_documents/Dana_Ford_35.pdf) shows them under the carrier bearings?

What does the sleve and thin shims that only fit on the outer pinion bearing shaft do? Does that get used in place of the crush sleve if wanted?

 

[brinker88]

1.) Actual backlash should be what the manufacturer states.
2.) You should have done your research better. That link you posted clearly shows external style carrier bearing shims.
3.) As for setting your pinion depth, you should have made a set up race (grind the outside down so it slides into the 3rd member for easy removal)
4.) The shims and CRUSH sleeve is for the outer carrier bearing is for setting your pinion pre-load.


You obviously have no IDEA how to set up a differential properly. You need to sit down and do some more reading before you dig yourself deeper in debt and frustration. Sit down and read this. Don't SKIM read it, but actually READ it until you UNDERSTAND it.

http://www.ringpinion.com/Content/H...tions/Yukon_Installation_Kit_Instructions.pdf

 

[nooch450]

1.) Actual backlash should be what the manufacturer states. (so .006-.0010) i read some people say thats wrong and it should be closer to .015"
2.) You should have done your research better. That link you posted clearly shows external style carrier bearing shims.That link i posted shows the "shims" between the carrier and bearings, the ones that came out of the housing were between the carrier bearings and diff housing
3.) As for setting your pinion depth, you should have made a set up race (grind the outside down so it slides into the 3rd member for easy removal)Nitro instructions say nothing as far as pinion depth and how would i go about doing this? I did grind the outer race of the old bearing to be able to do this but the nitro instuctions just say change the depth based on the contact patern....
4.) The shims and CRUSH sleeve is for the outer carrier bearing is for setting your pinion pre-load. I figured this but what would the shimms even do on that side of the pinion?


You obviously have no IDEA how to set up a differential properly. You need to sit down and do some more reading before you dig yourself deeper in debt and frustration. Sit down and read this. Don't SKIM read it, but actually READ it until you UNDERSTAND it.I have never done this befor and the fact that the rebuid kit does not include the same style shims doesnt help, also the fact that the nitro instructions are about as broad as you can get doesnt help. I appreciate the link and i will read it.

http://www.ringpinion.com/Content/H...tions/Yukon_Installation_Kit_Instructions.pdf

see my respones in red

Also changing the pinion depth changes the backlash and the pattern so how do you go about setting either one properly without guessing and checking a million times?

 

[brinker88]

Guess & Check is the name of the game, my friend. You have to be patient to get it right. Read through that link I posted for you. It helped me the most. And I have no idea why there would be shims AND a crush sleeve in the 3rd member when you first took it apart. Usually you don't use your crush sleeve and just set the bearing preload via shims the first time through. I also don't use the lock nut when setting up the pinion. It has a tendency to gall the threads. I just use a standard nut and check the preload as I tighten it. And 0.015" backlash is WAY too much play. http://www.therangerstation.com/tech_library/4wd_Front_Axles.html

For what it's worth, I haven't heard much good out of Nitro. I always use Yukon for their superb installation kits, bearings, directions, quality, and of course, their stickers.

Post up some photo's of where you're at now as well as your current backlash, pinion pre-load setting, and the thickness of the shims setting your pinion depth

 

[nooch450]

SO if my gear contact is too deep but backlash is good do i want to move my carrier away from the pinion and push the pinion out more or do i want to put a smaller shim behind the pinion and move the carrier / ring gear closer to the pinion?

One thing changes the other lol

 

[4.0B2]

One thing changes the other lol

that's the joy of regearing...
put a thinner shim under the pinion, see if that's the right way...

trial and error, mostly error.. just do NOT give up and use it on a bad pattern.

 

[nooch450]

that's the joy of regearing...
put a thinner shim under the pinion, see if that's the right way...

trial and error, mostly error.. just do NOT give up and use it on a bad pattern.

Oh trust me I refuse to run a poor pattern...

Another thing I question is the carrier Preload... and why are my shims not under the carrier bearings? But instead on the axle housing side...



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[4.0B2]

it varies depending on axle.. I think.

mine are not under the bearings, makes it easier... you don't need setup bearings this way.

 

[nooch450]

it varies depending on axle.. I think.

mine are not under the bearings, makes it easier... you don't need setup bearings this way.

Mine are external also... do you have just 2 thick ones? One on each side of carrier between the diff housing and outer bearing race? How did you set Preload on the carrier?

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[brinker88]

Make or buy a case spreader so you can put some more shims in there. You want the carrier to be TIGHT in there (as in tap it in with a rubber mallet tight). Dont set the CARRIER bearing pre-load too tight in your set up stages as it's a PITA to remove the carrier then. When you get your final pattern with your final backlash setting, add exact thicknesses of shims to both sides to tighten the pre-load up. If you do make a case spreader, DO NOT open the case more than 0.020" as you can tweak the housing (especially on an aluminum case like the D35's)

 

[nooch450]

How do I know how much Preload to put in and how will i add just a little bit when there are only 2 thick shims?

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[4.0B2]

you need some more shims IF the stock ones won't work. On my d35, I ended up using one of the stock thick ones and using shims to space the other side to get what I needed.

 

[nooch450]

How do I know how much Preload to put in and how will i add just a little bit when there are only 2 thick shims?

Also as of now I can get the carrier 90% in by hand but than the last 10% needs to be tapped in with a rubber mallet.
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[4x4junkie]

You need different thickness shims.

I bought a Yukon installation kit when I did mine, probably half it's content weight was in a couple dozen of those thick carrier bearing shims. It sounds to me like you possibly got the wrong installation kit maybe (like a Jeep rear D35 kit).

Like Brinker is saying, it's guesswork. The very first time you do it it's gonna take you a number of tries. As you do it more & more, you'll get better at it.

The link he posted along with some others are right above here in the Axles FAQ post if you need to read some more on the subject.

 

[nooch450]

Thanks for the help guys!

Whats the procedure you guys use for carrier Preload?

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