First off. I obtained this idea from Jeepaholics Anonymous.
I have to give credit where credit is due. Their write-up is here.
Stock yokes on the Dana 30 and Dana 35 (or 35C) utilize a strap and bolt to hold the u-joint in the yoke. I kept blowing this and the yoke out once/twice a year on my Dana 35. I decided to do something about it.
After reading the article on Jeepsaholics Anonymous. I decided that converting my yokes to U-bolts is the best method.
You will need:
- Precision Universal Joint u-bolt kit P/N: 534-10
- 5/16" drill bit
- WD40 or other lubricant for the drill bit
- basic hand tools (sockets and wrenches)
- remove your existing strap and bolts and remove the driveshaft from the yoke.
- Take your 5/16" drill bit, your drill, and the WD40 and drill out the four holes in the yoke for your new u-bolts. Warning: Pay close attention to the drill bit as you are gonig through the yoke. You do not want to go to far and puncture your yoke seal on the differential.
- Make sure the nuts have a flat area to rest against on the backside of the yoke. Also, you will have to enlarge the front of the holes a bit to fit the new u-bolts. Use the drill to enlarge the front of the holes very carefully. Periodically check the fit with your new u-bolts.
- Clean all metal shavings from the yoke and install your driveshaft onto the yoke. Tighten down the u-bolts evenly as you would with the u-bolts for your leaf springs.
I have around 15,000 miles on this new u-joint upgrade for my rear Dana 35. I have not had any problems with blowing u-joints in my rear driveshaft since I have completed this task. Prior to this I kept blowing the u-joint in contact with the Dana 35 yoke because the straps would not hold tight and would allow the u-joint to move around in the yoke.