Yukon Gear Master Overhaul Kit For Model 35 Diff

Howling rear axle in a Jeep Cherokee XJ, Wrangler YJ or TJ, Comanche or early Grand Cherokee? Or a 1970s AMC Hornet, Javelin or Eagle with a rear end that drips and clunks? All of those use the AMC Model 35, the axle most people call the Dana 35. The Yukon Gear and Axle YK M35 master overhaul kit has the bearings, seal, shims and hardware to rebuild that rear quietly or to set up new gears after a regear.

What the master overhaul kit does in a Model 35 rear

The Model 35 is a light semi-float axle. The pinion runs on two tapered roller bearings, preloaded by a crush sleeve and nut, and a shim behind the inner pinion bearing sets pinion depth. The carrier rides on two side bearings, and shims behind those bearings set side preload and move the ring gear to adjust backlash. Because it is a small axle often run behind larger tires, the bearings wear out early, preload goes away and the gear mesh moves, which is where the whine comes from.

Yukon lists the YK M35 contents as carrier bearings and races, pinion bearings and races, a pinion seal, a complete shim kit, ring gear bolts, a pinion nut, a crush sleeve, thread locker, marking compound with a brush, and a gasket. The bearings and races are Timken.

Symptoms of a worn Model 35

• Whine that follows road speed and changes when you get on or off the throttle
• Rumble that changes in turns, often a carrier bearing on its way out
• Clunk or slack when shifting from drive to reverse or on and off the gas
• Pinion yoke that moves up and down or in and out by hand
• Oil weeping from the pinion seal onto the driveshaft or yoke
• Metal on the drain plug or in the oil when you pull the cover

How to confirm before ordering

Make sure the noise is the axle and not tires, a wheel bearing or the transfer case. Our Dana 35 rear axle problems guide covers what wears out on this axle and when an upgrade makes more sense, and pinion bearing noise symptoms walks through the classic whine. Check the yoke for play, drain the oil and look for metal, and measure backlash with a dial indicator and magnetic base before you take it apart.

Fitment

Yukon lists the YK M35 for the AMC Model 35 rear in 1984-2001 Jeep Cherokee 4WD, 1986-1992 Comanche 4WD, 1993-1998 Grand Cherokee 2WD and 4WD, 1993 Grand Wagoneer, 1987-1995 and 1997-2006 Wrangler, and AMC cars including the 1968-1970 AMX, 1968-1974 Javelin, 1970-1977 Hornet, 1975-1980 Pacer, 1978-1983 Concord and 1980-1988 Eagle. Many of these vehicles were also built with a Dana 44, Chrysler 8.25 or other rear, so confirm the axle tag or the cover shape before ordering. The 2018 and later Wrangler JL Dana 35 is a different axle and needs JL-specific parts. Send us the year and VIN if you want us to check. A lower-cost USA Standard Model 35 overhaul kit is also available.

Install notes

• Yukon notes that 2003 and newer TJ Wranglers use 7/16 in ring gear bolts, while this kit includes 3/8 in bolts. For a 7/16 in unit, plan on ten Yukon YSPBLT-027 spacers.
• Pull the C-clip axles before removing the carrier: take out the cross pin bolt and pin, push each shaft in, remove the clip and slide the shaft out.
• Yukon's chart for the Model 35 lists 12-15 in-lb of pinion preload with new bearings, 6-8 in-lb with used, backlash of 0.006-0.011 in, and 55 ft-lb on both ring gear bolts and cap bolts. Check preload with an inch-pound torque wrench.
• Press bearings off and on with a bearing separator and puller, and use the marking compound to confirm the contact pattern.
• If the spider gears are chipped or the cross pin is grooved, replace them now with a Model 35 spider gear kit.
• Refill with the gear oil grade in your owner's manual, plus friction modifier if the axle has a Trac-Lok limited slip.

Is the Model 35 the same as a Dana 35?

Yes. AMC designed it as the Model 35 and it is widely called the Dana 35. Yukon lists this kit for the AMC Model 35 rear with the Dana 35 qualifier.

Will it fit my 2004 Wrangler TJ?

It fits the TJ Model 35 rear, but 2003 and newer TJs use 7/16 in ring gear bolts and this kit has 3/8 in bolts. Yukon says to add ten YSPBLT-027 spacers for those axles, or reuse good factory bolts.

Does it fit the Wrangler JL Dana 35?

No. The JL Dana 35 is a newer design and is not on Yukon's fitment list for this kit.

Can I reuse my ring and pinion?

Yes, if the teeth are not pitted or chipped. Note where the original pinion shim and carrier shims were, then reset depth, preload and backlash with the new bearings.

Do I need to replace the axle bearings at the same time?

They are not in this kit. Since the C-clip shafts come out anyway, check the axle bearings and seals, and look for a groove on the shaft where the bearing rides.