the backlash in my differential is waaay out of whack. it sounds like im gonna rip the teeth off the ring gear every time i shift (doesn't help that i have a manual). i was wondering, if i reset the backlash on the factory gearset (with 217,000 miles on it) will there be any problems other than noise? i've heard resetting gears after they have a pattern makes them howl but will i wear the gears out faster or am i just better off getting a new ring and pinion? also what gear ratio came in the 95 sports with the ax15 trans and the dana 35?

 

3.07 IIRC

 

Check that your pinion nut is tight.
That alone can play havoc with lash settings.
If you open it up and the teeth are sharp, its time for a change.

 

Sounds like your pinion bearings are toast. I'd replace them and as long as you haven't chipped any teeth or really worn the gears to a knife edge you should be ok.

 

just replace that Dana35, you won't regret it. Mine was doing the same thing and my pinion bearings were toast. I upgraded to a Chrysler 8.25 with 3.55s and a Non-disconnect D30 with 3.55s. Very worth the $100 spent and the 10 hours of work to get the axles swapped.

 

i'll try to describe how it sounds best i can. it makes a loud click when i: shift, let off the gas quick or get on the gas quick. the pinion nut IS tight but the PO snapped the bolt for the u-joint strap and tried WELDING the strap back on so needless to say i snapped it off in a parking lot, luckily i was at school so i could crawl into the garage and hack it back together quick just to get home but i think i may have over-tightened the nut when i put the yoke back on (i took it off to drill it out in a vice)

 

you probably effed up something when you took off and then replaced the pinion nut. Unless I'm mistaken there are certain torque numbers and procedures for if you ever remove the pinion.

 

Whenever you take a pinion nut off always mark the nut to the pinion shaft. When you re-install always put it to the same spot (or a VERY small hair past). If you over-tighten the pinion nut you will have too much preload on your pinon bearings causing premature failure.

 

I'd have someone watch your axle when you hear the noise... your springs could just be worn out causing the whole axle to move when its under a load. i've seen this before, and if your springs are original then they are well worn

 

thanks for all the help guys. would resetting the backlash on an original gearset have any repercussions other than noise? id just rather have a gear howl than the noise i have now

 

First thing I'd do, and you may have already done this, is make sure that the U-joint is held in the rear yoke properly. With the cobbled up weld job and then an additional repair, if that thing is not held in properly on one side it could certainly explain your described problems.

Now, if that is OK, how much lash are we talking about? With the trans in neutral, and the e-brake set, how far can you turn the pinion back and forth?