Dana 35 retainer pin bolt broken

[Alanmizzen]

Went in to change out my bearings on a c clip Dana 35 and noticed the retainer pin bolt head was missing. The retainer pin is not coming out so I'm assuming there is some piece of it left in there. Not sure how to proceed. Can I pull the gears out without pulling out the retainer pin?

 

Not sure how to post photos

[Alanmizzen]

https://goo.gl/photos/swrxbZMjETS1Bn9J7

[Alanmizzen]

Another photo

 

https://goo.gl/photos/TWkgJF8VYrta4wAA8

[big66440]

If you remove the right side " main cap" for the carrier bearing can you get a clear shot at it and drill it out?

[HOrnbrod]

^^ This, remove the cap. The below is what the shaft retainer pin looks like. How deep in the hole is the break? Can you wiggle or turn the shaft at all? If the break is after the thread maybe it'll come out with a small pencil magnet. If broken at the threads, try sticking a small screwdriver in the hole tightly while screwing it out ccw. There should be no pressure on it since the head is snapped off. 

 

[Alanmizzen]

I'll try taking off the right main cap and see if I can get a better angle at it. Updates coming. Thanks guys

[Alanmizzen]

Took off the cap so I could get a better angle and it looks like there is no bolt in there at all. I can shine a light right through. But now my screw extractor busted inside the hole so I guess I'm drilling that out now.

 

Is the bolt hollow? Wouldn't make any sense if it were. But the retainer pin is not coming out so there has to be something in there. Oh the joys

[Alanmizzen]

Annnnd now it's raining

[HOrnbrod]

Is the bolt hollow?

Nope. 

[Alanmizzen]

 

Is the bolt hollow?

 

Nope.

Ya Didn't think so

[HOrnbrod]

Better pic w. the shaft

 

[Alanmizzen]

Thanks. I've got to put it on hold for now. Going away this weekend and gearing up my Cherokee for the trip.

[MJCARENA]

Are you sure it is not a roll pin? Just have to punch it out.

[Alanmizzen]

I'm not sure. It has the hole for the bolt but I've never heard of the roll pin.

[Gene]

Are you sure it is not a roll pin? Just have to punch it out.

 

It actually does look like a roll pin. A lot like a roll pin.

 

Gene

[Alanmizzen]

So I should just be able to hammer it out? I did try knocking it a bit but not with much force. Unless there is a special way.

[HOrnbrod]

It's not a roll pin, it's a solid bolt/pin.  Common problem with them breaking in c-clip axles. Some PO broke it off then "made due" with the stub hanging in. If you can't get it out like I suggested above get one of THESE.

[Ataki]

I know on my 88 dana 35, there are no c-clips. the axles are held in by bearing retainers behind the brakes. mine DOES have a small roll pin where the cross shaft retaining bolt is. on those axles, you unbolt the retainers, and use a slide hammer to pull the axles free. I'm not sure what year the changeover happened, but I know my brakes and axle shafts are different from the 90 model I bought parts for.

[HOrnbrod]

 I'm not sure what year the changeover happened...........

 

1990

[Ataki]

 

 I'm not sure what year the changeover happened...........

 

1990

 

Ahh, okay.

[Alanmizzen]

I know on my 88 dana 35, there are no c-clips. the axles are held in by bearing retainers behind the brakes. mine DOES have a small roll pin where the cross shaft retaining bolt is. on those axles, you unbolt the retainers, and use a slide hammer to pull the axles free. I'm not sure what year the changeover happened, but I know my brakes and axle shafts are different from the 90 model I bought parts for.

Ya that's what I thought initially. So I took off what I thought to be the retainer plate and it was just a thin metal plate that wasn't attached to anything. So I just assumed it was c clip. Then I noticed on the diff cover it said 35 C. Which I'm assuming means c clip.

 

I may try the pin extractor that was suggested.

[HOrnbrod]

Don't assume. The 35C stamping does not mean it's a c-clip axle. The "C" stands for "Custom" meaning it came from the Dana factory not completely assembled. It has nothing to do with whether it has c-clips or not. All Jeep D35 rear ends are Dana 35C's.

 

OP, what year is your truck? How about editing your signature describing what you have. 

 

http://comancheclub.com/topic/51707-cc-members-create-a-signature-to-describe-your-mj/

[MJCARENA]

It's not a roll pin, it's a solid bolt/pin.  Common problem with them breaking in c-clip axles. Some PO broke it off then "made due" with the stub hanging in. If you can't get it out like I suggested above get one of THESE.

 He said he can shine a light thru it, can't be to solid.

https://www.ringpinion.com/b2c/ProductDetails.aspx?ProdID=1326

[HOrnbrod]

Well, I looked back to some of the OP's previous posts; he states in one post has an 88. That means a non-c-clip D35 if it's the original. If this is so, the retainer pin is a roll pin.

 

No idea what this means then:  "So I took off what I thought to be the retainer plate and it was just a thin metal plate that wasn't attached to anything. So I just assumed it was c clip."

 

Good luck OP...........

[big66440]

I agree with Hornbrod OP it would help out a lot if we knew what you were working on, I took a closer look at the pictures and it might just be a bolt in axle D35. Do you see any c clips at the end of the axle shafts?