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Dana 35 4.11 Rebuild Like I mentioned in Post #160, I picked up a set of stock 4.10/4.11 axles off of a guy a few hours away that pulled them from a 1995 YJ 2.5L 5-speed. I completed the front axle build and swap back in April 2025, but due to being either busy and/or experiencing poor weather...

What a long, busy weekend. Friday evening I pulled the tank, tried to install the tow hitch and bumperettes, and gave up on the tow hitch part. Just installed the bumperettes. I left the tank out for continued work the next few days. Saturday morning I started bright and early around 7 AM on...

Hard to say. Hopefully you’re almost at a resolution.

Something really weird is going on with that tire carrier. I don’t think it’s specific to the wheel, because the YJ also had the 15x8 Renegade wheel which is the same as the TJ gambler wheel. Same 5.5” BS and 8” width. The YJ did only come with a 29x9.5R15 instead of 30x9.5R15, but still….the...

4 would be plenty for anything a YJ can do. Anything larger just becomes harder to route. Nothing wrong with 2G, but a bit overkill. When I built mine I ended up using 4 gauge welding wire and I mimicked them to stock lengths and routing but used military terminals. All is well.

Nothing zaps energy like failed plans. The gearbox I ordered is clearly not the one from the photos. It has a clunk when I shake the pitman arm back and forth, so no way I’m installing that on my Jeep. It has a drop pitman arm, while the one I bought had a stock arm in the photos. The stock box...

Busy weekend ahead. Should be out of work early tomorrow and with Monday off, I should be able to accomplish 3.5 days of work. I’m supposed to receive the new u-bolt plates Saturday, the OEM steering gear arrives tomorrow, and the Curt towing hitch arrived today. The rear axle is painted, and...

Well, good news on the steering. Like I've mentioned before, I initially bought a BBB steering gear, and then while I had "back in stock" alerts turned on for Lares steering gears, those showed back up and so I ordered one. Two steering gears at my disposal. I already had the BBB hanging on the...

I worked on the toe a bit more. Think I got it right where I want it….if my measurements are correct, then I’m around 0.25° toe-in, which is the max spec. It feels good to drive. Hopefully being at the max of the spec doesn’t wear the tires out quickly. It feels good to drive now, doesn’t...

Not sure. I know it presses into the uppers pretty tight, and not as tight as the lowers, but I would assume that is pretty much by design due to where the lugs are relative to the bumpers. Also, the bumpers land on different parts of the tire down low depending on the size of the tire. I think...

No pictures to provide (I’ll grab some next time I make an adjustment), but I picked up some bleepinjeep alignment plates, which bolt to the rotor and provide places to measure so you can set your toe angle. I’m not 100% sure I got it right, so I will be digging back in soon. When I was done...

Ahh, so the water pump pulley hits the aftermarket electric fan. My personal solution would be to delete the electric fan and put the stock clutch fan back in. I too am curious why you had to do what you did at the skid plate though. Sounds like something is off.

I’m not sure what a belt wheel is. Can you show us pictures?

The shaft is probably bottoming out on whatever the center of the diff is. Usually a cross style center pin that connects all the spiders together. Just depends on the actual construction of the locker you have. I have a feeling if you trimmed off 1/8” or so, you’d probably be able to seat the...

That to me sounds like the shaft is too long and needs to be trimmed. That can be relatively common with some aftermarket differentials. Are the shaft’s stock? I would probably trim the shaft, leaving the nuts not very tight would make me nervous.

Somebody cut your cowl drain hose. I would just order one off eBay, or MTS makes them new. I'm not sure if they are any good, but they make them.

Interesting. If you are having to add 3/16" to the 1.22" bumpers, I suspect the 1.62" might still be correct, and maybe the issue with them is the carrier after all? Obviously your carrier issue is worse than I thought, since the wheel is hitting it. That makes me think if the carrier was fixed...

So this post was 53 minutes ago, and I just went back out there. Absolutely nothing has changed besides the exhaust cooling down during that time frame. I now have this much clearance by comparison: I think I have a heat expansion problem. I think SS expands quite a bit and might be growing...

The exhaust on this thing is really kicking my ass. The tailpipe is hitting the crossmember again. I got my new tires installed and then drove around for a bit. When I got home, the pipe was hitting. I parked it and checked it later and it was not hitting, it was back to having about 5/16” or so...

@TRevs I got another data point. It’s nothing new really, but it confirms what I expected. I installed my new 15x7 spare with 215/75R15 tire, and the 1.62” snubbers worked perfectly. I put it up there with the 1.22” still on the tailgate, and that didn’t work. They basically didn’t even touch...