IFS Dana 35 rebuild

[turboexplorer]

I found out last weekend finally what my problem was in the truck with the grumble in the floor. The right outer bearing on my IFS Dana 35 in my 98 5.0L is going out. I think I am going to just pull the diff and rebearing the whole thing. I have done the GM 10 bolt in my 79' Trans Am 4 times (until I spent money for a real carrier so not to break it under a trans braked slicks launches at the track) Anything I need to know about this D 35? That outer bearing, does it have to be pressed in? I can get a full bearing, skim, seal, crush, etc, everything through Randy's ring and pinion for $235. Or is there a better option? (That kit is all timken stuff to) Any rebuild thread on these? Searched for an hour didn't find one. Anyways, let me know if there is anything goofy with this diff! Thanks!

 

[Turdle]

I am not certain of this, but I think there are 1/2" holes on each side of the diff housing, which facilitate a spreading tool. The housing must be spread to remove the carrier bearings.

 

[IZwack]

Since you've done the GM 10-bolt, then you should know pretty much everything about the Dana 35 since the GM-10 is almost a straight copy of the Dana 44 and the Dana 44 is just a slightly larger version of the Dana 35.

 

[pdmustgt]

Don't need a case spreader it slides right out with help of a pry bar. Seen to many spread the case too much wraping the case then you are screwed.

 

[turboexplorer]

Comes out with the pry bar no problem for me to do there. About getting it back in do you just need to bop it in or is it pressed in I have access to press so that's no big deal if it needs to be done that way. And of coarse more will make sense to me when I get it out. The carrier part not worried about just the two end bearings where the CV's go in. That axle that goes to the pass side is it just like the GM 10 where its c clipped inside the spiders and it just floats on the end and the cv just hooks on that and rides? Am I correct? Had CV's out of coarse but couldn't see much as to how this case is put together. Sorry if I sound kinda dumb just live 300 miles from my old shop so don't have access to as many things.

 

[IZwack]

Dont use a press to get the carrier in - you'll fracture the housing (its aluminum). And there are no C-clips on the front axle.

 

[turboexplorer]

I meant press for the little side bearings axle bearings. Is the carrier hard to get in and out? My 10 bolt you just had shims on the side and it just kinda rolled in and you then put the caps on. I guess I need to pull it (when I get back from my honeymoon two weeks from now) Or find a blow up of the diff, that will help me see the whats all going on there. Can't be to complicated its a diff