PML Dana 35 Differential Cover

Description

Volume: 0.5 quarts over stock

Dimensions: Click here for dimensions.

Depth is 3.5 inches inside.

Number of Bolts: 10

The design of the PML Dana 35 differential cover works with a variety of applications.

Benefits:

Extra capacity
Fins and cast aluminum construction for cooling
Thick walls
Drain hole and magnetic plug to simplify maintenance
Follows stock cover profile

Applications

This differential cover fits the rear Dana 35 differential. Jeep models from 1984 to 2004 and some Ford trucks and SUVs may be able to use this cover:

1987 to 1995 YJ Wrangler
1997 to 2001 TJ Wrangler
1984 to 2001 XJ Cherokee & Wagoneer
1993 to 1998 ZJ Grand Cherokee
1999 to 2004 WJ Grand Cherokee with spacer (see installation below) or lifted
Ford Trucks and SUVs may have this axle for the front but usually do not have space for a larger cover

Always check to verify differential and clearance for a larger cover. Configurations vary. A larger cover may contact sway bars, gas tanks or skid plates.

Some Ford SUVs have a Dana 30 (PML part number 5058).

For Jeeps, other possible differentials include the Chrysler corporate 8.25 ((PML part number 9864) and the Dana C213 (no PML cover available).

Click on image to view larger.
Dana 35 (PML cover) on a 1999 Grand Cherokee WJ. 10 Bolts. About 9½ inches wide. One bolt centered on bottom.

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Chrysler/Dodge 8.25 Differential Cover, 10 bolts. About 12 inches wide. Bottom has flat edge. One bolt centered on the bottom.

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Dana 44 C213 stock cover on a 2006 Grand Cherokee. 12 Bolts. Flat on bottom with two bolts centered along bottom.

Installations

This PML differential cover for the Dana 35 was installed on a 1999 Grand Cherokee 4.0 4x4 WJ. The sway bar was a bit too close to the larger PML cover, so the mechanic fabricated and installed a 0.125 (1/8 inch) spacer on the sides where the sway bar connects.

Also installed on this WJ: PML transmission pan part number 9862 and front differential cover part number 5058

Click on image to view larger.

First image: Stock rear cover on a 1999 Grand Cherokee 4.0 WJ. There is about 1½ inches between the stabilizer bar and the stock cover. Jeep is on a lift since the stock cover is otherwise hard to see and access.

Second image: View from the ground looking up at a PML cover installed on a Grand Cherokee. To gain clearance for the larger PML cover, a spacer was installed on the stabilizer bar.

Third image: 1/8 inch spacer on stabilizer bar shown in this picture on a Jeep Grand Cherokee.

Specifications

Spacers for Sway Bars

Some sway bars do not allow enough space for a larger, aftermarket differential cover. It may be possible to use a spacer for the sway bar to increase clearance.

If you need spacers, one of our customers with a Grand Cherokee has recommended these: Iron Rock Offroad 1 Inch Sway Bar Spacers. (Thanks Ross!)

Installer must verify fit and function. Information for reference only.

Drain and Fill/Level Check

This PML differential cover has a drain hole on the bottom and a fill hole on the front. A magnetic drain plug, a plug for the fill hole, and mounting bolts are included.

This cover does not have a location for machining for a temperature sending unit.

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Inside of PML Cover

PML Dana 35 rear differential cover has an open interior and the shape is simlar to the shape of the OEM cover. The flange sealing surface is large and machined flat for a secure seal to the housing.

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