Replacing clutch packs in a Dana 35 - Page 2 - AUSJEEPOFFROAD.COM Jeep News Australia and New Zealand

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Old 29-12-2010
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OK. Did this today - I haven't driven it as yet. Just letting the RTV harden before I fill with oil and take it for a test.
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Old 30-12-2010
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Drives very well.

A few tips for those that decide to try this in the future. The diff centre is simple to remove - just follow the FSM detail.

Dismantling the limited slip diff is simple too. Particularly when you have worn clutch packs which reduces pressure between the side gears and pinion gears. Once you have the pinion mate shaft removed, put a wheel upside down on the ground with an axle standing up in it. Then sit the diff on top, using the axle spline in the side gear. Rotate the diff by hand which should cause the pinion gears to rotate in the housing an ulimately pop out. Depending on how tight you clutch packs are, you may have to compress one side - I used a wood working clamp.

The side gears and clutch packs should then just slide out.

Soak the new clutch packs in diff oil for at least 20 mins before installing them in the diff. Putting the new side gears, clutch packs, and clips in place is simple. Having to compress them to get the new pinion gears in is much harder. Again, I used a wood working clamp and some clever levering but it was a difficult job, particularly when it came to putting the thrust washers in behind the pinion gears. A piece of threaded rod, a few washers and nuts to suit would have helped compress the side gears. I don't know how much simpler the job would have been, but I would have started with that as a tool if I were to attempt this again.

The rest of the job is as per the FSM.
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