DANA 35 Nitro 4.88 Gear install help.

[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)

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[nooch450]

But how do I measure the Preload?

I feel like there would be a more accurate Preload spec like the pinion Preload... not just "tight"

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[brinker88]

Unfortunately, there really isn't any way to "measure" the carrier bearing pre-load. You just have to get a feel for it.

 

[nooch450]

Unfortunately, there really isn't any way to "measure" the carrier bearing pre-load. You just have to get a feel for it.

What if I record pinion Preload, than install carrier, check Preload again, subtract the 2 and multiply by the gear ratio?

So say it's 10 lbs with no carrier installed than 12 with carrier installed so x 4.88 gears = 9.76 lbs of carrier Preload.

Does that makes sense?

What is the carrier Preload spec anyway?

 

[brinker88]

No it doesn't. Pre-load means how much pressure is on the race pressing against the bearing. The preload on the pinion or the gear ratio doesn't matter when setting the carrier bearing pre-load.

Here's some good info I found via a google search:

http://classicbroncos.com/forums/showthread.php?t=209237

http://www.pirate4x4.com/tech/billavista/Gear_Setup/

 

[4x4junkie]

What I did was spread the case (housing) just barely enough to where I could wiggle the carrier out by hand. Then noting exactly how many turns on the case spreader bolts to reach that point.

Find whatever shims you need to attain that same level of resistance while wiggling the carrier back in... Release the spreader = bearings preloaded.

Alternatively (which I think is the "book method" of doing it), spread the case to whatever the installation spec is (0.015" for carrier installation), find your shims for the carrier to have slight resistance wiggling it in, then release the case against the bearings.

Be real careful with a spreader, it's very easy to spread a case too far and ruin it (go only the very minimum amount needed).

 

[Sasquatch_Ryda]

Just FYI....after reading through the install manual that came with my new Yukon Zip locker, yukon states not to use a housing spreader at all on aluminum 3rd members.

I have always just added a couple extra thou to each side so the carrier needs to be installed with a dead blow, never had an issue.

 

[nooch450]

Its either this with .013 Pinion Shim

or this with a .012 pinion shim

But i dont think any of this matters becasuse im havimg inconsitant backlash measurments arount the ring gear and it seems to happen when the pinion is clocked at a cirtain spot... Its ranging from .004-.010, i think these nitro gears may need to be exchanged for some yukons... I am not very happy with the quality so far...

This is what my 8.8 pinion looked like when it arrived, im suppost to recieve the replacement set tomorrow but im thinking about exchanging everything...

 

[4.0B2]

wow.. I've never heard great stuff about Nitro... but I've never saw stuff like this either. I have G2 gears. I like Yukon and G2 stuff.

are you torquing your carrier cap bolts to check your backlash?
remember you are working with an aluminum housing...

 

[nooch450]

wow.. I've never heard great stuff about Nitro... but I've never saw stuff like this either. I have G2 gears. I like Yukon and G2 stuff.

are you torquing your carrier cap bolts to check your backlash?
remember you are working with an aluminum housing...

Yes I torqued them to 55 ft lbs like the instructions say after tapping the carrier in with a dead blow.

Pinion has Preload enough to not be loose.

Should I just ask for replacement yukon gears?

I don't think this .006" change on the backlash when I check it in multiple spots is acceptable.....

Im really ****ing pissed right now.

I hope nitro gear/ jamesoaksenterprises will be willing to eat all this shipping cost because this is bullshit!

 

[4.0B2]

Yes I torqued them to 55 ft lbs like the instructions say after tapping the carrier in with a dead blow.

Pinion has Preload enough to not be loose.

Should I just ask for replacement yukon gears?

I don't think this. 006" range on the backlash is acceptable.....

Im really ****ing pissed right now.

I hope nitro gear/ jamesoaksenterprises will be willing to eat all this shipping cost because this is bullshit!

PM Jim before you start going off and cussing... Link this thread to him. Give him the chance to work things out.

personally, I'd get Yukon. But idk how that'll work now on a replacement set.

 

[4.0B2]

I keep all of mine at .008" backlash. .006" is a tad tight but I know people that run that. I'm not recommending you run it, I'm just saying that I've seen people do it with no issues.

 

[nooch450]

I keep all of mine at .008" backlash. .006" is a tad tight but I know people that run that. I'm not recommending you run it, I'm just saying that I've seen people do it with no issues.

You misunderstood.

The backlash varies from .004" - .010" depending on where the pinion is clocked.... so .006" of inconsistent backlash.

Considering the spec is. 006"-.010" I don't think .006" of backlash change throughout each pinion rotation is acceptable.

I think it should be. 002" max...

I emailed james oaks and told him I would like to speak with him on the phone and that I wanted to exchange all these nitro products for Yukon products.

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[Jim Oaks]

I won't be able to call you until Monday. Although I don't know how that's going to help. You tried to install them, you can't, and now you want to return them and get Yukons.

I am curious to know what the P/N is on the D35 install kit. The invoice looks correct, but I'm wondering if you got a D35 install kit for a rear end as mentioned above. Can you look at the packaging and let me know?

FWIW, I've never had anyone have a problem with this brand before.

Nitro Gear says the backlash for the D35 is 6-10 (.001" inch)

This is a master kit for a D35 rear axle:

And this is one for a D35 front TTB:

Instructions:

Here are the Nitro Gear instructions: http://www.nitro-gear.com/storage/Nitro Gear Installation Guide.pdf

 

[4.0B2]

I just don't see how the ring and pinion will you varies like that on backlash... Something doesn't seem to add up.