Birty Dastards Jeep Club
Tech Forum => Workshop => Topic started by: sprintagogo on August 26, 2009, 12:23:42 AM
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Just a quick rundown of the steps involved. This is actually the Chryco 8.25 with Trac-loc but the Dana 35 is almost identical to work on.
Remove diff cover and catch the escaping oil then remove the cross pin securing bolt (8mm head shown in the centre of this picture) The Dana has some kind of torx head and general consensus suggests a 1/4" 12 point wrench will fit but I didn't have any luck when I tried and ended up using a 7mm 6 point which just about worked.
(http://i288.photobucket.com/albums/ll188/sprintagogo/crosspinbolt.jpg) (http://i288.photobucket.com/albums/ll188/sprintagogo/crosspininplace.jpg)
Then slide the cross pin out of the way but it can be left partially inserted if it will stay still.
(http://i288.photobucket.com/albums/ll188/sprintagogo/crosspinup.jpg)
Once the cross pin is out the spider gears look like this
(http://i288.photobucket.com/albums/ll188/sprintagogo/cclipinplace.jpg)
Push the axle shaft inwards slightly to reveal the c-clip which then needs sliding out of its groove and removing
(http://i288.photobucket.com/albums/ll188/sprintagogo/shaftpushedinwards.jpg) (http://i288.photobucket.com/albums/ll188/sprintagogo/cclipremoved.jpg)
Once the c-clip is removed the shaft can be slid out of the axle casing
(http://i288.photobucket.com/albums/ll188/sprintagogo/shaftandcclipb.jpg) (http://i288.photobucket.com/albums/ll188/sprintagogo/shaftandcclip.jpg)
Use a claw hammer or prybar under the lip of the seal to remove it with no need to remove the bearing if it is not faulty
(http://i288.photobucket.com/albums/ll188/sprintagogo/clawoutseal.jpg) (http://i288.photobucket.com/albums/ll188/sprintagogo/bearing.jpg)
Then clean out the axle tube and fit new seal with a little sealant to make sure there is no leaks around the outside. The new seal can be tapped into place with a hammer and some flat metal bar so you do not damage the seal body
(http://i288.photobucket.com/albums/ll188/sprintagogo/newseal.jpg)
It makes sense to do both sides at the same time as the cost of the oil/RTV/lsd additive is far more than the cost of the extra seal if you have to do it all again later. before replacing the axle shaft put some gear oil onto the seal lips.