A friend of mine has an early 90's ZJ with a D35 rear. Its got an EZ Locker in it that's seriously pooched.

We just need it back on the road (its the DD, not the wheeler) so we're trying to figure out what we can swap in. I'm a Toyota guy, so I don't know what works with what in the D35's. Can anyone tell me what years/models of D35's have compatible side/spider gears? Its got rear disc brakes (if that makes a difference), 4 liter engine, and an auto tranny. Not sure if its a c-clip axle or what the gearing is.

Also, can the EZ locker be pulled and the stock side/spider gears re-installed without removing the carrier from the housing and having to re-setup the R&P?

Hmm, no one else is around I guess. OK, for the most part all of the parts on the Dana 35C series are interchangeable to some extent. At times you may have to swap out several parts to make one part swap over.

The first Dana 35C's (1984-1990) were your basic setup, 1.13" shafts with 27 splines. Brakes were 10x1.75" and they used Vented drums. The axle shafts were non-C-clip and used pressed on bearings and bearing retainer plates.

In 1991, the Dana 35C was changed from Non C-clips to C-clips. The brakes were also changed from the 10x1.75" to 9x2.5" drums. These were non-vented drums.

Now, here comes the confusing part. The earlier Dana 35C's used standard carriers but sometime around 1993 they started using ABS carriers even if the Jeep wasn't equipped with ABS. These carriers differed by the bore hole were the side gears mated with the carrier. Side gears have sort of a mushroom shape. The stem area is about 1/4" wider on a non-ABS then an ABS. These aren't interchangeable. Although technically, you could make a sleeve to fit an ABS side gear into an Non-ABS carrier. (This is what Tractech did with their Gearless locker.) The other option is to swap the whole carrier, otherwise, there is no difference in the housings.

Dana 35C's were used in XJ's from 1984-2001. They also had an option for a Dana 44 (1987-1990) and a Chrysler 8.25" (1991-2001). YJ's used the Dana 35C from 1987-1995.5. Grand Cherokee's used the Dana 35C from 1993 to present. Some Grands are equipped with an Aluminum Dana 44. TJ's used the Dana 35c from 1996-2006.

I'm not sure about Grands, but I'd suspect that they are equipped with ABS so they would have the ABS carrier so if you stick with 94-06 you should be OK. I think the most common will be the XJ in any salvage yard though.

You might check the Sales forum and see if anyone has spider gears and side gears for sale. You'll also need the thrust washers that sit behind the spiders.

Oh and you should be able to remove the EZ without taking the whole carrier out. It's a bit tough since you're working in a small area but can be done. You'll need to raise the rear axle and take teh tires as well as the calipers and discs off. Then use a 1/4" 12pt box wrench to take the lock pin/bolt out of the side of the carrier. The center pin should slide out now. Pushing the axle in 1/2" should release the C-clips. Then you need to pull the center dog teeth out while not losing the springs. (I forget if the EZ uses poppet) Then you have to wiggle out the side gears. Depending on how much room the cast carrier has it could be easy or take some time. It should come out though.

damn Jeffy, again you amaze me. good job man:smokin:

even if you remove the carrier to swap the internals, you should not have to make any adjustments to the R&P. All of the spacing is done on the pinion which you do not have to touch to remove the carrier.

damn Jeffy, again you amaze me. good job man:smokin:

I'm available for hire. :smokin: