Dana 35 Front or Rear Master Bearing Kit, Timken

A rear-end whine that comes and goes with the throttle on a 2001-2006 Jeep Wrangler TJ, a hum that builds with road speed, or a regear on the factory Dana 35 rear axle are the usual reasons people search for this kit. Motive Gear R35JRLMKT is the Timken master bearing kit for the Dana 35 that uses 7/16 in. ring gear bolts. It bundles the bearings, seal, crush sleeve and setup consumables needed to rebuild the axle or set up new gears in one order.

What the master bearing kit does in a Dana 35

Inside the Dana 35 the pinion gear is held by two tapered roller bearings, one at the gear head and one near the yoke, with a collapsible crush sleeve between them. Tightening the pinion nut crushes that sleeve until the bearings carry the right preload. The carrier, which holds the ring gear and the differential, spins on two more tapered bearings in the housing, and shims behind them position the ring gear against the pinion. That geometry is what keeps the gears quiet. Once a bearing pits or preload loosens, the pinion moves under load, the contact pattern wanders and the noise starts. The Dana 35 is a light axle for its era, so bigger tires and deeper gears load these bearings hard. The kit replaces every one of them along with the pinion seal, pinion nut and ring gear bolts, so nothing worn is carried into the new setup.

Symptoms of worn Dana 35 bearings

• A whine that changes pitch between accelerating and coasting, a common sign of pinion bearing wear or lost pinion preload
• A constant growl or rumble that follows road speed regardless of throttle, more typical of a carrier bearing
• In-and-out play or wobble at the pinion yoke when you grab it by hand
• Gear oil seeping from the pinion seal again soon after a seal-only repair
• Metal glitter or flakes on the cover magnet or in the drained oil

Wheel bearing noise from the axle tube ends can sound similar. If the noise changes when you swerve left and right at speed, check the axle shaft bearings before opening the carrier.

How to confirm before you buy

With the Jeep safely supported and in neutral, grab the pinion yoke and push and pull it along the pinion axis; any clunk means the pinion bearings or preload are gone. Pull the cover, drain the oil and look at the magnet and the ring gear teeth. Most important for ordering: check your ring gear bolt size. Motive Gear sells a separate Dana 35 master kit, R35JRMKT, with 3/8 in. ring gear bolts, and lists it for Cherokee, Wrangler YJ and TJ, Comanche and early Grand Cherokee. This R35JRLMKT is the 7/16 in. bolt version. If you are adding gears at the same time, our Spicer Dana 35 3.73 ring and pinion is one option to pair with it.

Fitment

Retail catalog data for R35JRLMKT lists the rear Dana 35 in the 2001-2006 Jeep Wrangler TJ two-door and the 2004-2006 Wrangler Unlimited, and excludes the Rubicon, which left the factory with a Dana 44 rear. Because TJ Dana 35 axles appear under both the 3/8 in. and 7/16 in. kits, the bolt size on your ring gear is the deciding check, along with the axle tag. Not sure? Send us your year and VIN, or a photo of the ring gear bolts and axle tag, and we will confirm. More axle and gearbox parts are in our hard parts catalog.

Install notes

• Mark and remove the pinion yoke, pull the old pinion, and drive in the new races fully seated. A Lisle pinion bearing race driver set keeps them square.
• Set pinion depth with shims, then tighten the nut a little at a time on the new crush sleeve while checking rotating torque. Revolution Gear lists 12 to 15 in-lb of pinion preload for the Dana 35; an inch-pound torque wrench is the right tool for that reading.
• Press the new carrier bearings on, set backlash (Revolution lists .006 to .010 in. for the Dana 35) and read the pattern with the supplied marking compound.
• Revolution lists 55 ft-lb for the Dana 35 ring gear bolts and bearing caps. Use thread locker on the new bolts.
• Refill with 75W-90 gear oil. A Trac-Lok limited slip also needs friction modifier unless the oil already contains it.

Will R35JRLMKT fit my 1997-2000 Wrangler TJ?

Catalog listings tie this 7/16 in. bolt kit to 2001-2006 TJ models. Earlier Dana 35 axles, and some TJ axles, use 3/8 in. ring gear bolts and take Motive's R35JRMKT instead. Measure a ring gear bolt or send us your VIN before ordering.

Does it fit a TJ Rubicon?

No. The Rubicon left the factory with a Dana 44 rear axle, and listings for this kit exclude it.

What comes in the kit?

Timken carrier bearings and races, Timken inner and outer pinion bearings and races, a crush sleeve, pinion nut, pinion seal, 7/16 in. ring gear bolts, a cover gasket or RTV, and marking compound with a brush.

Can I reuse my old crush sleeve?

No. A crush sleeve is a one-time part. Once it has been collapsed it will not hold correct preload again, which is why the kit includes a new one.

Do I need new gears too?

Only if the ring and pinion are chipped, pitted or badly worn. Good original gears can go back in with new bearings, but they must be set back to their original depth and backlash, and the contact pattern checked with the marking compound.

What gear oil does the Dana 35 take after the rebuild?

75W-90 gear oil. If the axle has a Trac-Lok limited slip, add friction modifier unless your oil already includes it.