DANA 35 Nitro 4.88 Gear install help.

[Jim Oaks]

I think it will vary if he doesn't have the proper bearing preload. I know I had to beat the crap out of my diff with a plastic mallet to get it re-installed.

 

[nooch450]

The rebuild kit part number is MK M35-IFS

The kit did not come with a gasket, but came with a bottle of sealant. There were pinion shims but no carrier shims. All the correct bearings and seals are there too.

I had to purchase the carrier shims separately from spicer.

I have enough carrier Preload for the backlash to be accurate. I had to tap the carrier in with a dead blow hammer. I checked the backlash with the carrier torqued downthe to spec. I even pulled it back apart and reinstalled it and was getting the same inconsistent backlash readings. I even went as far as cleaning all the marking compound off the gears with the same results. There is a spot on the pinion that seems to have a "high spot" because when the pinion is clocked with this spot against the ring gear the backlash is .004 but in any other position i get .010" of backlash, the carrier and ring gear is spinning tight and true.

Jim,

I would deffinatly like to speak with you on the phone when you are available.

After the nitro 8.8 pinion was delivered to me shot and now these nitro d35 gears are not "true" I simply do not feel comfortable running nitro products.

I have no issues with your customer service or anything you did, I want to make that clear.

You have been responsive and helpful the whole time.

Thanks

Dominick





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[4x4junkie]

There is a spot on the pinion that seems to have a "high spot" because when the pinion is clocked with this spot against the ring gear the backlash is .004 but in any other position i get .010" of backlash, the carrier and ring gear is spinning tight and true.

Have you checked for a burr or anything on the pinion?
Up until now I've heard nothing bad about Nitro either (at least their gears anyway), this is a first for me as well.
Check that it isn't from a bearing too (cone out of round)

I don't think that's the right kit, as there's nothing on the D35 TTB axle that gasket would fit. Nor do I see any D35 TTB carrier shims in that pic.

Edit:
Neither one of them is a D35 kit, the D35 has 8 ring gear bolts, not 10 or 12 as shown in those pics.

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.
.

The FSM says to spread the D35 housing 0.015" for installing the carrier (differential), 0.010" for removal (I was wrong above, now corrected).

I trust the FSM over any of the crap Yukon spews out in their literature (especially the dangerously low ring gear and bearing cap bolt torque specs they give for the 8.8").

 

[nooch450]

There is no burr or anything I can see on the pinion that would be causing false readings.

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[Sasquatch_Ryda]

Anything stuck behind the ring gear and carrier mating surface? I usually prep them with a large flat file just to make sure.

 

[nooch450]

Anything stuck behind the ring gear and carrier mating surface? I usually prep them with a large flat file just to make sure.

No I cleaned it really well than tapped it on with a dead blow making sure the mating surface was tight.

The backlash is tight on every 360 of the pinion. If the ring gear was "wobbling" the backlash would be inconsistent in a different way if that makes sense. Its only tight with the one spot of the pinion contacting the ring gear regardless of the position the ring gear is clocked at...

 

[Jim Oaks]

Post your exact problem so I can use that post as a reference when I call Nitro. I need to know the exact problem (which I understand to be inconsistent backlash), and all the possible causes and things you've tried to do to rectify it. That way I can cut through the BS when I'm talking to them.

If you're making an error on the install, it's not going to matter if you're installing Nitros or Yukons. If the gear isn't 'defective', Nitro will not want to fully refund them, so make sure you've checked every possible cause of the inconsistent backlash.

 

[Jsommers]

My buddy and I just installed 4.88 nitro gears in my dana 35 & 8.8. We got them to set up perfectly fine and they are quiet and run perfectly fine. It took lots of trial and error but they had a good pattern and everything.

 

[nooch450]

Jim,

Considering that I seem to be the only one with these issues with the nitro gears im going to attempt to install the replacement 8.8 gear set in my rear tonight and see how that goes. (hopefully all goes well)

As far as the Dana 35 TTB gears this is what is going on.

-I have carrier preload (new shims with same sum as old shims)
-I had to tap carrier in with a deap blow to get it in
-I was able to get a decent gear pattern as seen above (good pinion depth and the pinion has preload)
-The ring gear is flat on the carrier and it looks good
-I am getting inconsistant backlash readings (they range from .004"-.010")
-When I get a tight backlash measurment it is always when the pinion is clocked one cirtain way (i marked the pinion, whenever that spot on the pinion is facing the ring gear reguardless of the position of the ring gear I have tight backlash. To me that means the pinion has a high spot. (no wonder i was having a hard time shimming it)
-I dont see any visual problems with the pinion, everything was dissasembled, cleaned and reinstalled to make sure there was nothing causing this problem

I can let you know anything else you need to know when you call me.

Once again, you have been great to deal with.

Thanks,
Dominick

 

[4.0B2]

are you sure the carrier is not bent? that'd cause the same problem..

did you seat the ring gear on the carrier properly and TORQUE it down to spec?

also you have slack in the pinion, i.e. crush sleeve not crushed properly, it might cause something like that.

I really wish I was near by, I'd come lay an eye on it.

 

[nooch450]

If the carrier was bent or off than I would be getting tight backlash on one side of the ring gear and lose on the other. I have tight readings only when one side of the pinion is contacting the ring gear. Regardless of where on ring gear the pinion is contacting it. The ring gear is flat on the carrier and it is torqued down to spec.

The pinion is also tight and has preload.

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[4.0B2]

okay yeah. Makes sense. We had a tight spot on the pinion on a Jeep we were regearing Saturday, turned out to be a bad pinion bearing.

It was tight at the same spot on the pinion every time, no matter which direction we turned it.

 

[Jim Oaks]

nooch, you replaced all the bearings right?

 

[nooch450]

okay yeah. Makes sense. We had a tight spot on the pinion on a Jeep we were regearing Saturday, turned out to be a bad pinion bearing.

It was tight at the same spot on the pinion every time, no matter which direction we turned it.

What do you mean by turned it? Like in the bearing race?

Ill pull the pinion out one last time and make sure the bearing is clean and reinstall it again when I get home.

The bearing should be good though because it came out of the good working front diff.

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[nooch450]

nooch, you replaced all the bearings right?

The carrier bearings are new, the pinion bearings are old and I ground out the center to slip them (tightly) around the pinion to change shims / aid in installation.

The diff was disassembled while in working condition and everything appearer to be good, so the bearings im using for setup should be good. The pinion turns with resistance (Preload) and it turns smooth.

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