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Old 02-18-2014, 02:12 PM   #1
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d35 vs d44 comparsion

So as my math makes sense however my knowledge isn't as professional regarding jeeps as some of you guys, with the d35 27 spline, vs stock d44 can the d35 become stronger?

Based off the USA Alloy shafts which claim to be 35% stronger then stock. I am curious because im running 35s on stock d35 shafts with a posi rear and waiting to upgrade. Based off the charts:

The axle shaft strength tested by Warn Ind:
F8.8= 6,500 (lb. ft.)
D44= 4,600-5,000 (lb. ft.)
D35C= 4,000-4,300 (lb. ft.)

Therefore if a D35 was upgraded 35% stronger does that mean the D35 would be theoretically rated for 4500 +++ Lbs?
It seems to make sense however i am wondering if this is realistic, and who is running 35's on alloy shaft d35's? Open, Posi, or Locked?

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Old 02-18-2014, 02:21 PM   #2
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Your axle is only as strong as it's weakest component. Sure you can spend some coin on some heavy duty shafts but it's just passing the buck down the chain. Next thing you know you'll probably wished you saved for a full upgrade.

At least the Turdy-5 has some reason to have a fan page. http://www.billhughes.com/dana35c/

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Old 02-18-2014, 02:24 PM   #3
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Your shaft may take 4000 lbs but the rest of the unit will most likely die a horrible death with 35s even on an open diff. Yea a lot of people do it, but for the sake of reliability is it a good idea?
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Old 02-18-2014, 05:06 PM   #4
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So what breaks exactly then ? 1200$+ rear end isnt very optional, a guy i knew ran chromollys on 37s with a locked d35 before , after he went to one tonnes
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Old 02-18-2014, 06:23 PM   #5
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My next bet would be your ring&pinion seeing there's not much tooth lash. That, or your teensy spider gears, then there's your paper machet housing and we can't forget about the c clips.

You can do way more with 1200 then you think in an axle. Hell you could even find an 8.8 for free to 300 dollars with the gears you need and a LSD. That is if you don't have a different ratio already but who puts money into a 35.

Read this http://www.jeepforum.com/forum/f12/w...ks-d35-223663/
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Old 02-18-2014, 06:29 PM   #6
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Point is axle shafts are relatively cheap to replace, and easier then sourcing a new carrier and/or housing if/when it grenades.
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Old 02-18-2014, 06:49 PM   #7
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Don't let me persuade you into thinking you're d35 is a time bomb. There's just way more reliable units out there. And by replacing your shafts your just putting more of the 'give' the stock shafts had onto the guts of your rear pumpkin. I've never had a problem with a 35, but then again I've never wheeled one. And never will if my wrenching powers have anything to say about it.

If you want modest reliability and you pull your dif cover (inspect) time to time you will be fine upgrading your shafts. It's just that IMO there's better ways to pour your hard earned greenbacks into your jeep.
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Old 02-18-2014, 07:05 PM   #8
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I appreciate your advice. Up here there are no D44's around right, i have searched for months at salvage yards, used part companys, etc. The only thing remotely close was 1100$ plus shipping but then i'd have to regear also. I was looking at the G2 version of a super 35 with, 30 spline, detroit locker, etc. However it is 1200$. + install because i would be skeptical of doing a super 35 upgrade myself. Then theres a 8.8, my buddy told me i am looking into 150$ roughly for axle, then e brake cables , then regear, locker, wheel spacers, Truss kit, adapters, and a lot of time and messing around.

If you weld the dana 35 spider gears would that allow them to live a bit longer ? as opposed to a locker. My problem with the dana 35 is not so much the housing or diff cover, it is the scare of the thing breaking in the middle of a mud hole in the middle of nowhere.
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Old 02-18-2014, 07:29 PM   #9
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Yea if you welded your spider gears then you'd definetly toast a shaft or two. And if you upgraded those it's likely you're ring&pinion would chip a tooth. And if you cryo froze treated your R&P ($) then you'd most likely end up back at your carrier you welded together. If your not afraid to learn some new stuff look for an 8.8 and fab up your perches and shock mounts.

I'm personally waiting on some spindle mounting flanges so I can run a full floating ford 9" with d60 outers. But I'm expecting to really dump some dough into my project before I'm done. If you feel like learning read around on pirate, google, and explore your options. That's what's awesome about dana stuff, you can Frankenstein all sorts of different models sometimes decades apart and come up with something that was dirt cheap, and still accepts nothing but stock parts (from 13 different models).
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Old 02-18-2014, 07:30 PM   #10
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And no you will not find a bolt on 44 for less then a thousand bucks. Unless I win the lottery, finish my 9, and feel generous with my spare parts.
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Old 02-18-2014, 07:31 PM   #11
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If jeep felt just the added weight and tow capacity of TJ unlimited justified only making them with D44 (even with stock tires and gears) you know jeep knew it took very little extra load to justify the need for the D44 upgrade
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Old 02-18-2014, 07:39 PM   #12
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If jeep felt just the added weight and tow capacity of TJ unlimited justified only making them with D44 (even with stock tires and gears) you know jeep knew it took very little extra load to justify the need for the D44 upgrade
Damn straight.

And where in canada are you burden?
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Old 02-18-2014, 08:01 PM   #13
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Old 02-18-2014, 09:19 PM   #14
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?...your teensy spider gears, then there's your paper machet housing and we can't forget about the c clips....
Damn, this guy has me scared to drive home... Lol
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Old 02-18-2014, 09:23 PM   #15
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Damn, this guy has me scared to drive home... Lol

Yep. Spend enough time reading on here and you'll be afraid to leave your driveway with a d35.
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Old 02-18-2014, 09:56 PM   #16
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30 spline chromoly shafts with a full case locker, often referred to as a Super 35 kit will allow you to run 35" tires locked on a Dana 35 with really no worries, even on difficult trails. Jerry has mentioned a few rigs he has seen in Johnson Valley running 35's on super 35 kits.

I, among many others, ran a stock Dana 35 on 33" tires for years (10 years in my case) with no problems. They are not these toothpick axles people make them out to be. Don't lock them without axle shaft upgrades, stay 33" or under, and drive smart and you should be just fine.

That said, I decided to buy a Dana 44 from a 2001 TJ that needed work, turned it into a small project, and swapped it in for well under $500
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Old 02-18-2014, 10:00 PM   #17
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30 spline chromoly shafts with a full case locker, often referred to as a Super 35 kit will allow you to run 35" tires locked on a Dana 35 with really no worries, even on difficult trails. Jerry has mentioned a few rigs he has seen in Johnson Valley running 35's on super 35 kits.
When Jerry mentions that he means Superior's super 35 kit. Not the shafts that are imported from China.
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Old 02-18-2014, 10:01 PM   #18
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When Jerry mentions that he means Superior's super 35 kit. Not the shafts that are imported from China.
I would assume that's a given. You get what you pay for. Plus, you can't buy superior kits anymore after they went out of business
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Old 02-18-2014, 10:03 PM   #19
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I would assume that's a given. You get what you pay for. Plus, you can't buy superior kits anymore after they went out of business
They're extremely hard to find. I actually know someone selling a brand new superior super 35 kit...
I almost bought it myself but decided to replace the whole axle.
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Old 02-18-2014, 10:18 PM   #20
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They're extremely hard to find. I actually know someone selling a brand new superior super 35 kit... I almost bought it myself but decided to replace the whole axle.
That's thinking. I don't polish turds that won't shine. Neither should you.

Oh man I've got a new quote.
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Old 02-18-2014, 10:21 PM   #21
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I would assume that's a given. You get what you pay for. Plus, you can't buy superior kits anymore after they went out of business
You still planning on Bozeman man?
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Old 02-18-2014, 10:32 PM   #22
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Paper machet housing lol love it
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Old 02-18-2014, 10:40 PM   #23
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You still planning on Bozeman man?
Yep, probably a 95% chance I'll be there for fall semester this year. Me and my jeep of course
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Old 02-18-2014, 10:41 PM   #24
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been Jeepin' 45 years.......stay easy on the right pedal, and you'll be fine with stockers....
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Old 02-18-2014, 10:46 PM   #25
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Yep, go heavy on the pedal, get it bouncing, with a little shock load and..............
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Old 02-18-2014, 11:08 PM   #26
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That's thinking. I don't polish turds that won't shine. Neither should you.

Oh man I've got a new quote.
Obviously you've never heard of superior's super 35 kit if you think that
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Old 02-19-2014, 05:14 AM   #27
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haha , well that sucks for TJ's then, if you can't find a old d44 then theres the super 35 kit however super 35 is out of business and only g2 is left however you guys seem to be against g2. Outside that theres the 8.8 but setting it up and buying everything will run you over 1000$+ especially when you regear it. Then theres the alloy shafts but according to recent jeep news, they'll kind of fix the shaft problem but then i'll have carrier troubles
Hard world to run 35's half properly
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Old 02-19-2014, 05:30 AM   #28
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Obviously you've never heard of superior's super 35 kit if you think that
A built 35 is still not as strong as the 44. Its ring & pinion is much smaller. Sure you can upgrade axles but it will never match a 44, or an 8.8
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Old 02-19-2014, 09:27 AM   #29
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I am running Alloy USA chromo shafts and 35s 3 spd. Auto and open Diff with 4.56 gears. No problems in 10 years and I go to Rausch Creek all the time and run some really tough trails. Drive smart and you will be fine. I carry a second set if shafts with me and learned how to replace them. I drive 70 mph for 3 hours to Rausch, wheel it for 2 days and drive home. Then normal street use, no issues what so ever. I don't have $1500 to drop on an 8.8 so yeah.
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Old 02-19-2014, 12:06 PM   #30
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Thanks Sahara, cool to see someone running what i asked. I was curious because i always read d35's are useless to upgrade outside of the super 35. After talking to my buddy the other day about options (he just installed a 8.8) he was telling me if he had his time back he would of just upgraded the d35 for the amount of messing around he went through. I may upgrade to chromo shafts and not beat it silly. Worst case scenario i blow up some things with the axle, i will just swap in my spare d35 haha for free, then if i have troubles again i may just fix it. Being a student, its bad enough owning three vehicles, then trying to upgrade a jeep ( non DD ) on top of it

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