Dana 35 Rear Differential Master Bearing Kit R35RWMK

A whine from the back of a 1999-2004 Jeep Grand Cherokee WJ or a 2002-2003 Liberty KJ that gets louder on the gas or on the coast, a growl that tracks road speed, or a pinion seal that will not stay dry are the usual reasons people land on this kit. Motive Gear R35RWMK is the Koyo master bearing kit for the Dana 35 rear axle in those two Jeeps. It holds every bearing, race and setup part needed to rebuild the axle or install a new ring and pinion.

What the bearings do in a Dana 35

The Dana 35 is a semi-float, C-clip rear axle with a 7.562 inch ring gear. The pinion rides on an inner (head) bearing and an outer (tail) bearing, and a crush sleeve between them sets how hard those bearings are loaded. The carrier spins on two side bearings, and the shims behind them decide where the ring gear sits against the pinion. When any of these bearings wear, the gears move away from the position they were set to, the tooth contact walks toward the edge, and the noise starts.

Symptoms that point to this kit

• Whine that changes between acceleration and deceleration, the classic sign of pinion bearing wear or lost preload
• A steady rumble or hum that follows vehicle speed and does not change with throttle, more typical of a carrier bearing
• In-and-out play at the pinion yoke, or a clunk when you go from drive to coast
• A pinion seal that leaks again shortly after replacement because the pinion is moving in its bearings
• Bright metal on the cover magnet or in the drained gear oil

How to confirm before you buy

With the driveshaft unbolted, grab the yoke and try to push it in and out and side to side. Any movement you can feel means the pinion bearings or preload are gone. Then spin the yoke slowly and feel for roughness. Our acceleration vs deceleration whine guide explains which noise points to which bearing, and the pinion bearing noise guide covers what a rebuild costs. A WJ with the 4.7 and a 45RFE or 545RFE can also hum from the transmission, so rule that out with our 45RFE noise diagnosis guide. If the gear teeth are pitted or scored when the cover comes off, plan on gears as well, such as the Spicer Dana 35 3.73 ring and pinion.

Fitment

Motive Gear catalogs R35RWMK and its bearing set for the Dana 35 rear in the 1999-2004 Jeep Grand Cherokee WJ and the 2002-2003 Jeep Liberty KJ. Those vehicles were also built with other rear axles, including the Dana 44 and the Chrysler 8.25, so read the axle tag or count the cover bolts before you order. The earlier Dana 35 used in the 1984-2001 Cherokee XJ, Wrangler YJ and TJ, and the 1993-1998 Grand Cherokee ZJ is cataloged under a different Motive kit, and those bearings should not be assumed to interchange with this one. The kit is for the standard Dana 35 rear, not the 2018-up JL Dana 35 (M200). Bearings and setup parts only: no ring and pinion, carrier or axle shafts. If you are not sure which Dana 35 you have, compare the numbers on your old bearings and cups or send us your year and VIN. Our Dana 35 problems and upgrade guide covers identification.

Install notes

• Mark the bearing caps, pull the C-clip axles, then lift the carrier out and keep the side shims in order. A Dana housing spreader makes carrier removal and reinstallation far easier without damaging the case.
• Press the old bearings off the carrier and pinion. The clamshell bearing puller is the safe way to do it without scarring the journals.
• Revolution Gear lists a starting pinion depth of 0.045 in, 12-15 in-lb of pinion preload with new bearings, .006-.010 in backlash, 55 ft-lb on the ring gear bolts and 55 ft-lb on the caps for the Dana 35. Check your gear maker's sheet as well.
• Tighten the pinion nut in small steps and check rotating torque each time. If you go past spec, the crush sleeve must be replaced, not backed off. See crush sleeve vs solid spacer.
• Paint the ring gear with the supplied marking compound and read both the drive and coast sides before final assembly.
• Refill with 75W-90 gear oil to the bottom of the fill hole, adding friction modifier if the axle has a clutch-type limited slip.

Adding traction too? A Yukon Dura Grip posi for 27-spline Dana 35 fits the same teardown if your spline count and ratio match.

Does R35RWMK fit my 1997-2001 Cherokee XJ or Wrangler TJ?

Not according to Motive Gear's catalog. R35RWMK is listed for the 1999-2004 Grand Cherokee WJ and 2002-2003 Liberty KJ. The XJ, YJ, TJ and ZJ Dana 35 use a different Motive kit, so send us your year and VIN and we will match the right one.

Is a ring and pinion included?

No. This is a bearing and setup kit: Koyo carrier and pinion bearings with races, crush sleeve or shim pack, pinion seal, pinion nut, shims, ring gear bolts, thread locker, cover gasket or RTV, marking compound and a brush. Gears are sold separately.

Can I replace only the pinion seal instead of the whole kit?

If the seal leaks because the pinion has play, a new seal will not last. Once the crush sleeve has lost its set, the old bearings cannot be re-preloaded correctly, so the full bearing kit is the real fix.

What pinion preload and backlash should I use on a Dana 35?

Revolution Gear's setup chart lists 12-15 in-lb pinion preload with new bearings and .006-.010 in backlash for the Dana 35. Always confirm against the instructions that come with your gear set.

What gear oil does the Dana 35 take?

75W-90 gear oil, filled to the bottom of the fill plug hole. Add friction modifier if the axle has a clutch-type limited slip such as Trac-Lok.

Do I need special tools?

Plan on a bearing puller or press, race drivers, an inch-pound torque wrench to check pinion preload, a dial indicator for backlash and, ideally, a housing spreader for the carrier.