FRUSTRATED with setting new gears

[ryandavison]

i need to install a new ring and pinion in my rear end, which ive done before with help but now the problem is that i have lost my measurements of the backlash and pinion spacing from the last install. is there a good starting point or is this going to be just a complete trial and error till we guess close and can then get it right? my jeeps been down for a few months now and im eager to get it done, but i want it done right too. thanks! its in a 98 tj, and im running a stock c-clipped dana 35 with an old arb locker and stock 3.07 gears.

[Shadly1]

Yep. Buy an extra bearing or use your old one. Grind a layer out of the inside so it slides on and off the pinion without mechanical pressing. Take a guess on the spacers and torque it up. Check it with a grease pen or gear paint. Add or subtract spacers as necessary. When you nail it, take out the pinion and have the new bearing pressed on in place of your hollowed out one. You're still going to need a dial indicator for the backlash to do it right. You can rent those.

Hey man, if it was easy, everyone would do it!

[Linus]

You probably know all this but ...

I haven’t done a D35 before, but if it is like the D30, it isn’t real hard, just requires a lot of patience. In addition to your new gear set, you will need a master rebuild kit, and it should have instructions with all the specs. Concur with Shadly1 that you will want to keep the old bearings and grind them out so they slip on and off easily. It turns out that there isn’t much difference in the width of the bearings, so the adjustment is only a result of the new gears. Make sure you note where the shims go, between the bearings and the carrier (as in the 30) or between the bearings and axle housing (AMC 20). For reference, you might want to check out http://forums.corvetteforum.com/show...684&forum_id=3 sure, it isn’t a D35, but the guy has some good pictures and instructions. For a starting point, try and use the old measurements.

[Elusive]

Theres more to it.
The older ARB's have a master shim and are shimmed from the outside of the bearing on the left side. These shims are not standard and neither is the bearing.
So, a master install kit will do you no good as you can't use the carier shims or bearings. The good news is that ARB has awesome customer support and they don't even stroke you bad on price for parts. Call them up and tell them what you are doing. They are also in the Pacific Northwest, so you'd likely get your stuff the next day.. I get it to SoCal in about 3 days.
I can't recall if the TJ d-35 uses a crush sleeve, but you might need one of those as well.
Now..setting the gears. if you are going totally blind on the carrier bearings, put .030 uner the bearing on the passenger saide and shim the outside shims on the drivers side till the carrier is very snug going in. see where you are at and trial and error from there.
if the pinion dept is also unknown, you really might want to get some help.

[YJ 1 I]

This is a real pain I ruined a set of 4.88 by trying to slam it in before a trip!!! Take your time and do it RIGHT the first time don't rush like I did.

[mrchips]

TRY THIS,,,http://www.ringpinion.com/Default.aspx
IT IS A PRETTY GOOD BOOK, SHOULD EXPLAIN A BASIC SHIM THICKNESS TO START WITH AND THEN YOU CAN WORK FROM THERE,,

[mrchips]

they sell a book all about diffs, runs around $30.
all you need to know about diffs,,,,and setting them up