Can't believe this...I just took the cover off my Dana 35 and found out that some one broke the bolt. According to the Chilton's manual it's called the pinion gear mate shaft lock screw (that is broken). Every time I go to fix something on this Jeep I find that who ever owned it before me, messed it up. Was going to pull the axel and put in a new axel seal,it's leaking bad and ruined the brake shoes.
Any one know how to help me out of this jam, beside changing the rear end?

Thanks!-John

 

Heat up the carrier near the bolt hole and use a pick to turn the remainder of the bolt out, righty tighty - lefty loosey. Then buy a new bolt & little blue loctite just snug the bolt when reinstalling.

ETA:
If no joy:
http://www.etoolcart.com/fabbri-diff...actor-kit.aspx

 

Thanks!~Turbo XJ, I will try that tonight.
How does the guide and the drill bit get int there with such limited space?
Why are the drill bits up to 12 inches long...do they flex or bend?
Well I am going to try and heat the carrier and maybe I'll get luckey and the broken shaft lock bolt will come out. Since the threads are so close to the top of the hole... seems possible to me. If not I'll buy the extractor tool.
Just hated to get out of bed this am when I thought about this job.
Oh!~and surprised the bolts break on their own and seems pretty common.
Thanks!~John

 

Turbo XJ, you out there today?
I finally got time to look at the broken pinion bolt and it appears that some one has already drilled a hole right threw the center of the bolt.
It seems that they still couldn't get the bolt out.
It is not a straight shot unless you remove the two bolts and cap on the right side.
I got 2 easy outs, but the larger of the 2 still seems to small because it almost goes all the way inside the broken bolt.
I stuck in a small allen wrench in side of the hole of the broken bolt and found out it has been drilled all the way to the pinion shaft.
Going to try and get a larger easy out and heat the carrier tonight before using the larger easy out.
Any thing else I need to know?
Thanks!~John

 

B4 you heat it try easy out it might spin right out ....you can remove the cap just make sure you put it back exactly the way it came off and tourqe it back down..

 

Is it a broken bolt or just a roll-pin? I have had roll-pins in there before. If so, you just use a punch to tap it out.

 

Says ring gear bolts broke if I understood correctly