Yukon Gear Master Overhaul Kit For Jeep Wrangler JL Dana 35 200mm Rear Diff

A 2018-or-later Wrangler JL Sport or Sahara that has started whining from the rear, leaking at the pinion, or is about to get a ring and pinion swap for larger tires is the buyer this kit is built for. The Yukon Gear and Axle YK D35JL-REAR is a master overhaul kit for the newer-design Dana 35 rear used under some JL models, the 200 mm ring gear axle often listed as the Dana 35 M200. It is new, uses Timken bearings and races with Yukon seals and small parts, and includes Yukon's shim stacks and super shims for fine adjustment during setup.

What the master overhaul kit does in a JL Dana 35

When Jeep moved from the JK to the JL, the Sport and Sahara models got either an upgraded-design Dana 35 or a Dana 44 in the rear, while every Rubicon got a new-design Dana 44. The JL Dana 35 is not the same axle as the old YJ and TJ Dana 35, and gear sets and bearing kits for the older axle do not carry over. Inside, the pinion rides on two tapered bearings under preload and the carrier rides on two side bearings, with shims setting pinion depth, backlash and carrier preload. Once those bearings wear, the pinion moves under load, the gear mesh changes and noise follows. This kit replaces the wear parts in the center section so the axle can be set up correctly from scratch, whether you are reusing your gears or installing a new ratio.

Symptoms this kit addresses

• Rear whine that comes in at a certain speed and changes on and off the throttle
• Rumble from the rear center section after adding larger tires without changing gears
• Gear oil on the pinion yoke or the rear driveshaft from a leaking pinion seal
• Clunk at takeoff or loose feel at the yoke from lost pinion preload
• Bearing debris on the cover magnet or water-contaminated, milky gear oil after crossings

How to confirm before ordering

First make sure the noise is in the center section. Wheel bearings and axle shaft bearings at the ends of the housing make noise that changes in turns; center-section noise usually changes with load instead. Drain the oil and look for metal or water. With the driveshaft removed, spin the pinion by hand and feel for rough spots or end play, then measure backlash with a dial indicator and roll a gear pattern. If the carrier bearings check out and you only need to install new gears, the smaller Yukon JL Dana 35 pinion install kit may be enough; for high mileage, water exposure or noise, the master kit replaces everything.

Fitment

This kit is for the Dana 35 200 mm rear axle in the Jeep Wrangler JL. It does not fit a JL with the Dana 44 rear, which includes every Rubicon and some Sport and Sahara models, and it does not fit the older YJ or TJ Dana 35. Check the axle tag on the rear housing, the build sheet, or send us your year, trim and VIN before ordering. The JL front Dana 30 is a separate job that uses the JL Dana 30 front master overhaul kit. More differential kits are in the rebuild kits collection.

Install notes

• Mark the bearing caps and measure backlash and the existing pattern before teardown.
• Remove the rear axle shafts before pulling the carrier, and inspect the shaft seals and bearings while they are out.
• Use a side bearing puller set to remove carrier bearings without damaging the shims you need as a reference.
• Start pinion depth from the original shim, read the pattern with marking compound, and adjust using the supplied shim stacks.
• Bring pinion preload up slowly with the new nut and crush sleeve, checking rotating torque as you go.
• Fill with the gear oil grade listed in your owner's manual and change it again after break-in when new gears are installed.

Building the rear for bigger tires? Stronger 4340 chromoly JL Dana 35 axle shafts and an Eaton ELocker for the JL Dana 35 install while the axle is apart.

How do I know if my JL has the Dana 35 or the Dana 44 rear?

Every JL Rubicon has a Dana 44 rear. Sport and Sahara models came with either the newer Dana 35 or a Dana 44. Read the axle tag on the rear housing or send us your VIN and we will confirm.

Will this fit my TJ or YJ Dana 35?

No. The JL Dana 35 is a newer design with different gears and bearings than the YJ and TJ Dana 35.

Should I buy the master kit or the pinion install kit?

The pinion install kit is for lower-mileage axles where the carrier bearings can be reused during a gear change. Choose the master overhaul kit for high mileage, noise, water contamination or when you want every bearing new.

What bearings does the kit use?

Yukon builds this kit with Timken bearings and races, along with Yukon seals, small parts, shim stacks and super shims.

Does the kit include gears or axle shafts?

No. It covers the center section bearings, seals and setup parts. Ring and pinion gears, the carrier and axle shafts are separate.