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D-35 carrier removal question

w_howey

w_howey

NAXJA Forum User
Location
The Mudwest
It occured to me, I had never torn down a Dana rear before. So I went and started tearing down an axle I had laying in the parts heap.


I got everything out until I came to the carrier. The bearing caps are out, and it seems the only thing holding it in is friction against the bearings by the case. Am I correct? If it is I would assume this is what a case spreader is needed for.
 
I've never needed to use a spreader. I pry, turn the carrier a bit, wiggle some and pry again. When you hit the sweet spot it will pop out of there and fall on your head or whatever is under it. A pile of old blankets or something is recommended. I've never had much luck trying to catch and hold an oily carrier.
 
Hmmm... Alright. But if I had a spreader, this is what it is used for. Spreading the case open to slide the carrier in or out.

This is a spare axle,so I'm not worried about dropping the carrier. Its actually sitting on the tailgate of my 'Manche. Its awfully nice to be able to stand up and work, not sitting in some greasy mud hole on a trail somewhere.
 
Feed a rag into the gears, turn the yoke with a wrench. It'll pop right out.

Hale
 
This is how it is done

DIFFERENTIAL

REMOVAL

  1. Raise and support vehicle.
  2. Remove the lubricant fill hole plug from the differential housing cover.
  3. Remove the differential housing cover and allow fluid to drain.
  4. Remove axle shafts.
  5. Note the installation reference letters stamped on the bearing caps and housing machined sealing surface Bearing Cap Identification
  6. Loosen the differential bearing cap bolts.
  7. Position Spreader W - 129 - B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes Install Axle Housing Spreader Install the holddown clamps and tighten the tool turnbuckle finger - tight.
  8. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing Install Dial Indicator and zero the indicator [SIZE=+1]CAUTION: Do not spread over 0.38 mm (0.015 in) If the housing is over - spread, it could be distorted or damaged. [/SIZE]
  9. Spread the housing enough to remove the differential case from the housing. Measure the distance with the dial indicator Spread Axle Housing
  10. Remove the dial indicator.
  11. While holding the differential case in position, remove the differential bearing cap bolts and caps.
  12. Remove the differential from the housing. Ensure that the differential bearing cups remain in position on the differential bearings Differential Case Removal
  13. Mark or tag the differential bearing cups to indicate which side of the differential they were removed from.
  14. Retrieve differential case preload shims from axle housing. Mark or tag the differential case preload shims to indicate which side of the differential they were removed from.
  15. Remove spreader from housing.
INSTALLATION

If replacement differential bearings or differential case are being installed, differential side bearing shim requirements may change. Refer to the Differential Bearing Preload and Gear Backlash procedures in this section to determine the proper shim selection.
  1. Position Spreader W - 129 - B, utilizing some items from Adapter set 6987, with the tool dowel pins seated in the locating holes Install Axle Housing Spreader Install the holddown clamps and tighten the tool turnbuckle finger - tight.
  2. Install a Pilot Stud C-3288-B at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing Install Dial Indicator and zero the indicator [SIZE=+1]CAUTION: Do not spread over 0.38 mm (0.015 in) If the housing is over - spread, it could be distorted or damaged. [/SIZE]
  3. Spread the housing enough to install the case in the housing. Measure the distance with the dial indicator Spread Axle Housing
  4. Remove the dial indicator.
  5. Install differential case in the housing. Ensure that the differential bearing cups remain in position on the differential bearings and that the preload shims remain between the face of the bearing cup and the housing. Tap the differential case to ensure the bearings cups and shims are fully seated in the housing.
  6. Install the bearing caps at their original locations Differential Bearing Cap Reference Letters
  7. Loosely install differential bearing cap bolts.
  8. Remove axle housing spreader.
  9. Tighten the bearing cap bolts to 77 N·m (57 ft. lbs.) torque.
  10. Install the axle shafts.
 
what I always do is keep the bering caps in place with only a few threads in, so that when you pry on it the carrier will not hit you. and pry with a big ass pry bar. works every time.

but yes you are supposed to use a case spreader for this, just a waste of time in my opnion.
 
Finished today....

Its much eaiser to leave the bearing caps in place, put a pry bar through the carrier and use an impact to remove the pinion nut.

A large wrecking crow bar works VERY well for removing the carrier. The large bruise on my leg is testament to that.
 
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