DANA 35 Nitro 4.88 Gear install help.

[Jim Oaks]

I've been going back and forth with my sales rep about these today. He suggested the typical causes and I told him you already checked all that.

He told me:

I talked to shop and they said to make sure there is no Cosmoline on the gears as they sometimes come with to much in one spot. It sounds like this guy knows what he is doing. I am going to go pull another set of gears and see if I notice any problems with it. What ratio is he running? If needed I can send you another RGA and he can ship back the gears so we can look at. I know it is a pain and is not making Nitro look good, but it is Company Policy.

 

[nooch450]

I've been going back and forth with my sales rep about these today. He suggested the typical causes and I told him you already checked all that.

He told me:

I guess im going to have to send them back, just get me the RGA number and ill try to ship them out today if i make it home in time. Can you get me a replacement inner pinion bearing for the D35 from the manufacturer as well? I would hate to pull the new bearing off the bad pinion possibly damaging it just to re-use it.

I used your freeze and heat meathod to install it and it worked well BTW.

Thanks,
Dominick

 

[Jim Oaks]

I guess im going to have to send them back, just get me the RGA number and ill try to ship them out today if i make it home in time. Can you get me a replacement inner pinion bearing for the D35 from the manufacturer as well? I would hate to pull the new bearing off the bad pinion possibly damaging it just to re-use it.

I used your freeze and heat meathod to install it and it worked well BTW.

Thanks,
Dominick

Update:

Talked to Jeremy and he said there is obviously a high spot on the pinion. That can be fixed by deburring the gear with a Die Grinder and sanding disk. Or he said we can send you a call tag for the gear and swap it out for another set.

Do you want the call tag, or sand where you think the high spot is?

 

[Jim Oaks]

I went ahead and just requested the call tag.

 

[nooch450]

Thanks jim, I don't feel comfortable grinding the pinion. Let me know when they give you the #.

Thank you again for the quick response!

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[Jim Oaks]

I'll be emailing you a call tag. You should be able to print it out, stick it on the package, and drop it off with UPS.

 

[nooch450]

I'll be emailing you a call tag. You should be able to print it out, stick it on the package, and drop it off with UPS.

Ok sweet.

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[nooch450]

How does this new 8.8 pattern look?

This is with the pinion .002" deeper.

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[Jim Oaks]

I emailed the UPS label to you. Actually, it's a link to the label you can print out and stick on your package for UPS.

 

[4x4junkie]

How does this new 8.8 pattern look?

This is with the pinion .002" deeper.

http://i1059.photobucket.com/albums/t433/nooch450/2013-04-02_18-41-52_12_zpsf2852e4c.jpg

http://i1059.photobucket.com/albums/t433/nooch450/2013-04-02_18-42-12_667_zpsae0e8311.jpg

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Looks like you need a bit more pressure on it.
Try turning the diff using a wrench on a ring gear bolt while putting light resistance on the pinion, this usually gives a more readable pattern than if you're turning it by the pinion gear.

 

[nooch450]

Are these pics better?

Thanks you all for the help, I don't want to **** this up Haha

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[Sasquatch_Ryda]

Whats your backlash at?

I'd run that no issue.

 

[Captain Ledd]

I'm with Sasquatch. If your backlash is in spec I'd start buttoning her up.

 

[nooch450]

.011"-.013"

Its in spec. Thank you all.

Next time this should get easier and easier!

I just dont know how im guna do 500 4x4 miles while being easy on it to break in the front gears when its time...

The D35 gears we're shipped back yesterday morning for exchange. Ill post more pics when I receive the new ones and i get them all set up....



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[4x4junkie]

Agreed, looks good to me also.

I assume that "nick" or something right at the toe of one tooth is just the setup grease? (not the tooth itself)?