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Old 12-31-2010, 08:46 PM   #1
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Smile dana 35 regearing

Proud owner of an 03 tj freedom edition. Have a 3:07 dana 35 in the rear and a dana 30 in the front. I am wanting to regear the 35 and have heard that I have to regear the 30 the same as the 35 any truth to this? Also running 33x12.5's with a 4.0L 5speed. I currently use 5th gear as an extra edition to my highway use and have to switch back to 4th gear very quick! Wanting to switch to either 4:10 or 4:56 gears not sure which is better. Any input would be appreciated. I am an occasional offroader with no intent on rock climbing so please no comments on the 35 or 30 being a weak link. If i break an axle parts a readily availiable and can always upgrade to a 30 spline if need be. Also would like to put a good limited slip in the 35 but not sure if I need to get one in the 27 spline or save some $ and upgrade to the 30. I have no plan of switching to a dana 44 or ford 8.8 as I would never use them often enough to pay for the extra expense.

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Old 01-01-2011, 12:24 AM   #2
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You have to have the same gears front and rear. No way around it...you don't want the front wheels turning at one speed and the rear another. Lots of parts would break. The 35 is not a strong differential and when you go to bigger tires and a locker it can put a lot of strain on it. I have 99 with a 35 and I have 4:56 gears and an OX locker and upgraded axles but after all the money it is still the weakest link. I do a lot off road and the 4:56 gears are perfect with my 33 bfg's.

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Old 01-01-2011, 01:36 AM   #3
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Definitely go with 4.56 gears with your 4.0 and manual tranny and 33's. I upgraded my 35 to a Superior Axel Super35 with detroit locker and love it.
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Old 01-01-2011, 09:33 AM   #4
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Yes, you will need to regear both axles. You will also need to get new carriers for both the front and rear. Based on how you are describing use of the Jeep, 4.10:1 gears would be fine.
Since you will need new carriers upgrading to a TrueTrac in the rear would be a big improvement for occasional offroad use. It works very well offroad, is clutchless so will not need rebuilding or friction additive and will be a lot easier on the D35 than a locker would be. The TrueTrac only comes in 27 splines for D35s. IMO, if you think you need 30 spline alloy shafts you should be running a D44 or better, not throwing money into a D35.
You can put in a new open carrier up front and if you decide to get into wheeling harder later on, you can install a lock right or Aussie locker.
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Old 01-02-2011, 10:33 AM   #5
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Thanks to all for your input. Had the jeep for a couple of years now and just getting it ready for the trails. Its my daily driver and dont want to go to crazy with it just yet! But I will have to save for awhile to get the gears for her. Thanks again
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Old 01-02-2011, 09:39 PM   #6
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4.56 is perfect with 33's in my opinion.
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Old 01-03-2011, 05:28 PM   #7
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Old 01-04-2011, 06:17 PM   #8
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how is the 4.56 compared to the 4.10 on the highway? im thinking of doing the same.
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Old 01-04-2011, 09:06 PM   #9
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( New Ratio / Old Ratio ) * Old RPM = New RPM at same speed in same gear. For the OP, I'd go with 4.10 for your setup.
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Old 01-04-2011, 09:13 PM   #10
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It is not about opinion or onroad offroad. It is about putting larger tires on and needing to return the overall reduction back to factory specs or as close as possible. 4.0L with manual tranny and 33" tires = 4.56 gears.

Will the OP be happy with 4.10's probably but only because its better than what he has. But if you are going to spend the money to regear you just as well do it right.
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Old 01-04-2011, 09:37 PM   #11
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The carrier needs to be changed to go from 3:73 to 4:10? If so it's gonna cost me even more.
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Old 01-04-2011, 09:45 PM   #12
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Same carrier as far as I know.
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Old 01-04-2011, 09:57 PM   #13
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Thats what I thought. Must have misunderstood a post further up. thank you
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Old 01-04-2011, 09:59 PM   #14
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same carrier
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Old 01-05-2011, 11:28 AM   #15
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You will have to change carriers to go with anything taller. I went from 3.07 to 4.56 with the same 4.0, 5-speed and 33's. You won't be sorry, it will make it a different animal. Good Luck!!
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Old 01-05-2011, 12:55 PM   #16
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not to jack your thread, but what would be a reasonable cost for regearing d30/35 3.07 to 4.56 or 4.88 r&p/carriers/labor?
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Old 01-05-2011, 01:14 PM   #17
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not to jack your thread, but what would be a reasonable cost for regearing d30/35 3.07 to 4.56 or 4.88 r&p/carriers/labor?
The cost is around $1200 to $1400. Better do something different with the 35 though.
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Old 01-06-2011, 08:49 AM   #18
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Talking Got the gears!

Just bought 4.56 gears and a powertrax lsd and my local mechanic is gonna do the install next week. Parts and labor for $1000. I love ebay! Cant wait to see what she does offroad. Gonna try it out in a few weeks.
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Old 01-06-2011, 09:25 AM   #19
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Your going to break that D35c
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Old 01-06-2011, 09:42 AM   #20
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Unhappy

Dumping money into the Jeep D35 = Fail

Sorry Man.. Just the way it is.. Some people have gotten away with it but more than likely in the long run you will regret it greatly
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Old 01-09-2011, 04:19 PM   #21
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Already thought about breaking the axles. Have a buddy of mine that has two extra sets of 35 axles in case that does happen. Just tryin to fix up what I already have. If I had the money to spend and spent that much time offroad I would have to agree with the 35 being a waste to fix up. But shes my daily driver and I think the upgrade will be good for now but thanks for the input! Maybe I will be the exception!
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Old 01-09-2011, 04:24 PM   #22
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how is the 4.56 compared to the 4.10 on the highway? im thinking of doing the same.
4.10, as I once ran when I had 33" tires, doesn't quite restore the lost performance like 4.56 does. I was really frustrated after regearing to only 4.10 instead of 4.56 as all my buddies recommended. Go 4.56, you would be disappointed both on the highway and offroad with 4.10 as I was.
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Old 01-09-2011, 05:46 PM   #23
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4.10, as I once ran when I had 33" tires, doesn't quite restore the lost performance like 4.56 does. I was really frustrated after regearing to only 4.10 instead of 4.56 as all my buddies recommended. Go 4.56, you would be disappointed both on the highway and offroad with 4.10 as I was.
Jerry, would you recommend 4.56 with an auto as well?
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Old 01-09-2011, 06:33 PM   #24
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Jerry, would you recommend 4.56 with an auto as well?
No, 4.56 would not be appropriate for either of the two possible automatic transmissions. The ratio recommended for 33" tires depends on which automatic transmission you have. For the 3-speed 32RH used in 2002 and older TJs, 4.10 is appropriate for 33" tires. For the 4-speed 42RLE automatic transmission, you need to go all the way to 4.88 since the 4-speed's overdrive ratio is so high that the rpms it produces at highway speeds are too low and need to be brought up a tad to prevent engine lugging.
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Old 01-09-2011, 06:42 PM   #25
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No, 4.56 would not be appropriate for either of the two possible automatic transmissions. The ratio recommended for 33" tires depends on which automatic transmission you have. For the 3-speed 32RH used in 2002 and older TJs, 4.10 is appropriate for 33" tires. For the 4-speed 42RLE automatic transmission, you need to go all the way to 4.88 since the 4-speed's overdrive ratio is so high that the rpms it produces at highway speeds are too low and need to be brought up a tad to prevent engine lugging.
Thanks, runnin the 42rle, didn't really want to swap carriers. I have a really good friend was going to save me the labor cost for a Regear. That's how the budget is. Guess I'll keep flipping the OD switch til my economy recovers. Haha. 33x12.50 with the 3.73 is not super bad around town or on mild trails, but it aint what it once was.
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Old 01-09-2011, 08:21 PM   #26
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Got a question about a 05 SE model other than a lift and tires its stock but im debating on weather to get a locker or save money for later upgrades? I got the dana 35 in the rear with 3:73 gears but have no clue if its got the limited slip rear end, and if its any good as far as occasional trail ridding (when the wife allows me to she bought it so...) but I found a detroit ez locker for like 150 (also it says non abs) I wondering if I should get it for 150 or wait till i find something better!
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Old 01-09-2011, 08:32 PM   #27
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If it's got a LS you can't put a locker in it unless you change out the carrier.. Also since you got a D35.. Don't lock it.. Most of the time only bad can come out of it.. And since by the looks of your avatar you live in a snowy climate the auto locker will only be more of a hindrance since you wouldn't be offroading it that much to use the benifets of a locker, yet drive it in the snow all the time to notice the downside of a auto locker in the snow.. IF you got a Limited Slip.. Congrats and Enjoy

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