Need help for trail repair!!

[Special K]

I was on the Crown King run today and I broke my D35 axle (driver side). :mad: :mad: I got a ride out (thanks Jim, I owe you one) and got a new axle, but I need some help putting the new axle in. I have a Powertrax no-slip locker and I just don't have the technical skills to pull it apart on the trail. I am pretty desperate as my vehicle is stranded on the trail. I need someone that can help me replace the axle. I would be willing to pay for your time and effort. I am planning on going back out Sunday morning to do the repair. I also need someone with a vehicle that can get me back in there. I am not too far in on the trail so any stock 4x4 should make it. I would appreciate any help. Please PM me or reply if you are available.

[Special K]

Disregard my previous message, I got someone who is going out with me today. THANKS DESERTDAWG.

[RickBeer]

We could have started the Trail fix 101 early :D
Glad you got some help

[jim0352]

If you're gonna need any help, let me know. I can head back out there.

Jim

[D-Dub]

Let me know if you need some extra shafts.

Dave

[mingoglia]

If for some reason something goes horribly wrong and you can get it close to the trail head I have a trailer/truck and can drag it back for you. Good luck.

Sad thing about this is I just got back from 4 wheel parts in Mesa and the sales associate and I were talking about what plans I have for the Jeep. I told him I just picked up a 8.8 to swap out my rear. He said, "well the front is the one you really have to look out for".... 'nuff said, I took my price matched JKS Quicker Disconnects, my two 10k hooks that he charged me $4/ea for and left. ;-)

Mike

[Spongebob]

Kevin,

Did you get your jeep out?

[Special K]

Thanks for all the help that was offered. Thanks to a lot of help from Jim who drove me to get some new parts, and to Mike (desertdawg) and his nephew who went out with me to do the repair, I got my Jeep out. I'de also like to thank the good samaritans that came by helped us out when we were a little tired and frustrated. We didn't get off the trail until after 1 a.m., but the Jeep is safe at home.

[jim0352]

Good to hear you got the Jeep back safe and sound. Was there any other damage other than the shaft?


Jim

[desertdawg]

That was the first time I had ever replaced a broken axle so we ran into a couple of snags.:eek:

First snag was trying to get the pin out of the powertrax locker which was very tight. I learned not to pound the pin out so far that it jams up on the diff case, because it will not go back in without a lot of force. The pin was jammed up between the pinon gear and diff case with about enough room to fit two fingers back there. So we spent about three hours just trying to get the pin back in far enough so we could turn the carrier to get it in position to where I could use a pliers to extract it. What a PITA! Persistance and a little ingenuity finally paid off. Once the pin was out I was able to get the locker out and get on with the repair.

Next snag was trying to get the ABS gear off the new axle. Kevin was told that this gear was easy to remove ("NOT"). Kevin attempted to remove the gear while I removed all the metal chunks from the axle tube. Good thing Kevin bought a telescoping magnet which made removing all the metal chunks easy.

We were all tired and frustrated when a group of wheelers came along and offered their help. We finally got the gear off and proceeded to replacing the axle. We left the locker out and replaced it with the old spider gears Kevin had saved when we put the locker in. Replaced the fluid, cleaned up the mess and we were on our way. I finally got home at 3:30 AM. It was a looong night! At least my nephew had a good time, this was pretty much the first time he had ever been wheeling in his Taco. Here's some pics.

Here's that Trail Rated Dana 35 axle.:rolleyes:
http://www.virtualjeepclub.com/attachment.php?attachmentid=2532&stc=1&d=1128884277
Trail Repair 101
http://www.virtualjeepclub.com/attachment.php?attachmentid=2533&stc=1&d=1128884277
Perfect Trail Repair Conditions, Darkness, Dirt, and Rocks.
http://www.virtualjeepclub.com/attachment.php?attachmentid=2534&stc=1&d=1128884277

[OlneyJeeps]

Krap! I was all ready and looking fo an excuse to get out on the trail! Good to hear you made it back ok!

[Nnote]

What size tires and was it a 2.5 or a 4?

[BoggerBilly]

Glad to hear you got it back out fine. We felt bad leaving before the job was done but we were having all sorts of trouble with one of the xjs in our group and were just trying to limp it home. Maybe we'll see you on the trail another time. Hopefully under better circumstances.

[desertdawg]

Hey BoggerBilly!

Were you the Good Sam that helped us out that night?:D

[BoggerBilly]

That was me. Glad to have been able to help.

[desertdawg]

Yes, You were a big help to some weary and tired folks!:D

Hope to wheel with ya sometime!

Did you guys figure out what was wrong with the XJ?

[BoggerBilly]

Bad plug wires and a failing fuel pump. All better now.

[OlneyJeeps]

I (still) have a complete full floater kit for a 35 / 35c:
easy to install
will never see your tire/axle/brakes on side of road
2 axles
spindles
spare brake assemblies
2 warn locking hubs
extra locking hub
Retail $800+tax/shipping
gently (ok they stood up to 37's with a broken lock-right;)used price : $400

[live24wheel]

What actually caused the shaft to break? Were you hard on the gas or climbing through a tuff section or what? I have a Dana 35 with a Lock Right and am still trying to figure out what the limits of it are... lol i know i know but until the $$$ comes for the 44 its gotta last.

[OlneyJeeps]

The 35 in inherently weak (small shaft size). Because of the c-clip design (clip holds axle in), when the axle breaks, off comes the wheel and tire etc. The full float kit (yes I know I am trying to sell one) is great because it takes the weight stress off of the axle. Additionally, if the axle does break (usually the less expensive hub will break first) , it will usually not stop you (if you have an open carrier, you will lose drive to the rear, but can drive out on front wheel drive). More importantly, your tire will not fall off (scary!).

Like I said in prior post, this kit held up to 37's with a lock-right. The pins in the lockright snaped, causing the lockright to stay locked. The owner proceeded to drive on hard pavement untill one of the hubs striped (accounding for the new set of hubs plus one used spare)

[live24wheel]

what is involved in doing the kit?

[OlneyJeeps]

Steve's 12 step method:

Get beer from fridge

yank your old stuff out (remove c-clip from carrier if applicable)
put diff cover back on (assuming you had to remove for c clip)
fill diff with 90wt
Replace 1st beer with fresh beer
bolt spindle to axle housing ( 5 nuts actually )
slide hub assembly on
tighten spindle nut
slide axle in
slide locking hub over wheel studs
put tire back on
finish beer and replace with new beer

[live24wheel]

I like it, now I just need to win the lottery! :D

[OlneyJeeps]

Lottery: you can't lose if you don't play :eek: :D

[Special K]

What actually caused the shaft to break? Were you hard on the gas or climbing through a tuff section or what? I have a Dana 35 with a Lock Right and am still trying to figure out what the limits of it are... lol i know i know but until the $$$ comes for the 44 its gotta last.

I was climbing a hill when the axle shaft broke, but I wasn't hard on the throttle because I knew the axle is weak. I had a powertrax locker and it twisted the axle shaft right off at the spindle. I bought the Jeep used so I don't know how it was treated before I got it, but it was in good condition so I don't think is was abused. I had been up much harder obstacles before with no problems, so I guess it was just the axle's time to go. I had been told that with a D35 it is not IF it will break but WHEN.