Jeep Wrangler Dana 30 & Dana 35 Builds with 5.13 Yukon Gears

Maniacmechanic1

solid fixture here in the forum
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New projects.
Axles from a 1999 Jeep Wrangler.
Dana 30 front & Dana 35 Rear.
Getting 5.13 :1 Yukon Gears.
Old friend of mine local.
35 inch tall Off road tires.

Snowing today.
Lifted muscled carried into my basement not too long ago this morning.
Get started with teardown later today.
I took the diff covers off last night and drained the old gear oil out.

Complete fresh rebuilds by me.
I will sand blast them clean too myself.
 
I got the Dana 30 & Dana 35 apart this week.
Good Hard parts cleaned up in solvent.
Up early this morning.
Hookup my car trailer to my '99 Chevy Tahoe. Load the Jeep Dana diffs on & head to the car wash and power wash clean.
Buy 4-6 bags of Black Diamond Coal slag & Blast the Housings clean here on my farm.
Try & get them in Primer also today.
Sunday is Easter of Course.

Full Thrash working today Saturday.
 
well, congrats on having the skills to rebuild them, very few people do.
obviously detailed pictures of the process and tips would be nice
 
well, congrats on having the skills to rebuild them, very few people do.
obviously detailed pictures of the process and tips would be nice
All in the details. Right Tools.
Skills and experience.
It changed setup now with 2 -cut gears Vs. Old 5-cut gears.

5- gears highly prized.
Bought 2-sets New 5-cut for my Own Pontiac 9.3's. 4.30 drag race. 3.64 street .

Think Dana 60 still 5-cut. Have not bought used lately for anyone.
With 1000 HP + many have here in Illinois I expect to use someday soon again.
 
It took about 7 hours yesterday to Powerwash, Buy Supplies, Get home & setup to Blast with Black Diamond Coal Slag & Paint the Dana 30 & Dana 35 Jeep Housings.
Went through Five 50 lb bags of blasting media.
My Gasoline Engine Air compressor had no problems keeping up. It only has 9 gallon Twin Tanks.
W - Head radial compressor head. Puts out way more CFM than most shop air compressors, its the way to go if Your Sandblasting or media blasting.
Went through 1.5 gallons of 87 octane gas. Think I blasted for 3-1/2 hours alltogether.
Most of the rust was removed, 90-95 %. Terrible road salt rust 21 years old. Just Nasty to begin with.
Painted with VHT Gloss Black Roll Bar Paint 2 cans. A few bare spots, need to buy 1 more can to touch up.
 
yes it looks like its had a major clean-up and exterior rust removal,
much improved in appearance.
 
yes it looks like its had a major clean-up and exterior rust removal,
much improved in appearance.
Customer is Happy, sent him pictures.

I like My Evapo Rust remover better.
Not using my New 15 gallons EVR, For Pontiac parts cleanup of my own.
 
Off of work for the rest of the week.
Watching my boys.
Wife flies out to East Coast Maryland tonight.
Drive her to Midway airport.

Working on both diffs.

A tip ...
Try and use Vintage 1 single pinion depth shims.
Modern install kits have you stack them.
None the right size period in kits Given.
Rumaged through my Diff parts building since 1987.
Found a Vintage GM Shim right thickness I need to set the pinion depth I want.
Shims stacked want to split and spit out.
Should not happen but it does.
That much load under operation.
 
I finished building the 1998 Jeep Wrangler Dana 35 Rear Diff.
Get pictures up in the morning.
2 am Tuesday. Get some sleep.
Drive through Chicago traffic later this morning to get to Midway Airport.

The Front Dana 30 is bit tougher to figure out Shim packs.
Uses inboard shims on the carrier.

Working alone late at night is still best getting projects done.
Cuts into sleep only.
 
The Dana Rear Ends are made of superior steels and alloy iron.
The Diff carrier is actually 8620 Steel.
They make them small today for lighter weight & fuel economy.
Unless you buy a 3/4 ton or 1 ton Truck then they have Big Diffs.
Should all be 9 inch, Pontiac 9.3 drop out or a Dana 60. Work with what is given to you in this case 1998 Jeep Wrangler Dana 35 & Dana 30.
The Jeep only has 2.5 liter 4-cylinder.
My old friend installed 35 inch tires offroad mud & sudden no power left, his wife's Toy Jeep. Had a hard time getting up to highway speeds with stock 4.11 gears.
I installed 5.13 :1 gears in the D35 & will do the same in the front D30.
It will be like having stock driving capability back with new 5.13's.

I used generous backlash at .009" -.010" because extreme heat buildup is present in all modern small ring & pinion differentials.
Overloaded near all.

Install wheel studs from old axles that had bad bearing surfaces.
Paint outside to touch up later this week.
 
How did you determine 18 inch pounds of preload on pinion nut without torque wrench to know how tight to get it. Isn't it specific? I know it won't back off because it is a self locking nut.
 
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