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Dana 35 problem

Blackdog

Active Member
Joined
August 31, 2006
Messages
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City, State
Zillah Washington
Year, Model & Trim Level
2004 F-150, 2006 Ranger
I have a 97 Ranger 4X4. I pulled the Dana 28, and replaced it with a Dana 35. The Dana 35 has new 4:88 gears, bearings and seals. I'm using the Dana 35 axles that were with the differential.

When I was assembling the drivers side hub I found I could not install the spacer and "C" clip on the axle end because the axle didn't stick out far enough. I tried prying the axle out a little but it was out all the way.

Why won't the axle protrude out far enough for the spacer and clip? The inside end of the axle is held in by another "C" clip in the diff. I'm thinking that the gear installer moved the gear assembly while shimming it, the 4:88 gear is much thicker than the original 3:73.

Any ideas?
 






...did you buy this and it was un-assembled???...are you having this problem on just the passenger side or on both sides???
 






...did you buy this and it was un-assembled???...are you having this problem on just the passenger side or on both sides???

I bought a complete Dana 35 from a 1994 Ranger. I pulled the pig and axles, had the 4:88 gears installed then put them in my Ranger using my old beams and disc brakes.

This problem only exist on the passenger side.
 












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