So I replaced the bearings and seals on my '87 XJ, D35 and after only three drives of less than 10 miles total, the bearings exploded. Very new at all this, so looking for some suggestions/guidance on how or why that would have happened? I did do the disc brake conversion, which is what prompted me to redo the seals and bearings since I already had them accessible. Pics below if it helps at all.

 

Was that the tapered roller bearing with an inner and outer race?

 

So I cant recall by what means the rear wheel bearings are pre-loaded even in the normal situation, but I do know a spacer is required for the disc conversion

In theory, for your bearings to self destruct so quickly would mean they have been set up either with way too much pre load or freeplay, or have inadequate lube

An incorrect thickness spacer plate may lead to that?, mine is about 3/8"

Just something to think about. I have done quite a lot of forensic style analysis of failed machinery, which can often occur just after being worked on, and it is necessary to identify the failure mode before proceeding, such as failed parts, improper fitment, poor workmanship, procedures, lubricants etc etc

 

Yep

 

I got the TJ plate and drilled the holes out to match the axle flange in order to maintain the pre-load, as that's what the online community says to do. It is possible that there was not enough lube on both bearings, but considering the amount of grease I used I'm not too sure that was the case.

 

Do my eyes deceive me or is the seal in the inside?

 

Ya I think Kuro89 is on to something , The bearing may have been installed wrong . The rear end oil suppose to lube the bearing .

 

I've got the non-c clip so there's an inner and outer seal. It is entirely possible I screwed that up though. You can somewhat see what's left of the outer seal on the axle shaft below the parts of the bearing cage.

 

Looking at parts lists there is a an inner seal which baffles me as the dana 44 doesn't have an inner seal.
You likely have a preload issue on your modified backing plates.

As a side note i don't see why you can't ditch the inner seal and let the diff oil lube the bearings and ditch a maintenance item.


Wait, was your bearing retainer destroyed? How is it still on the axle? Do you have a pic of the axle/bearing before it went back in?

 

Looking at the axle the way the bearing has a pressed on keeper ring is that for a dana 44 because a dana 35 takes a different bearing and don't have a press on keeper ring .or am I wrong ?

 

Looks like a typical blown up Dana 35 to me. I wouldn't waste anymore money on it, find a Chrysler 8.25 out of another XJ and swap it in.

 

I have the non-c clip axle so it has a pressed on safety ring.

 

I am seriously thinking about going that route, but after all the work I did for that disc brake conversion I sorta don't want to scrap the project.

 

Unfortunately, the only 'pre-pics' I took was of the original setup as I was pressing it off. The retainer plate was still on the bolts on the flange. Once I undid the nuts the axle was able to pull right out since the bearing cage was destroyed.

 

You can put the same disc brakes on the 8.25.