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Old 01-09-2014, 11:36 AM   #1
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Strongest Dana 35

First off let me say, it is currently not possible for me to do a swap to anything else so I am stuck with a D35 (for at least the next two years). It is also not possible for me not to unleash my TJ on the dirt whenever time permits. So I am looking for the strongest Dana 35 axle shafts I can find. So far I've found some from Crown (don't care for made in China), Alloy USA and Ten Factory (don't know where they are made). Any suggestions?

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Old 01-09-2014, 12:04 PM   #2
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You can polish your turd by getting a C-clip eliminator kit with axle shafts and new 30-spline ARB carrier for about $1300.

or you can buy a bolt-in a Ford 8.8 from ECGS for about $1300.

Your call, but I'd never sink $1300 into a D35.....

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Old 01-09-2014, 12:11 PM   #3
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You can polish your turd by getting a C-clip eliminator kit with axle shafts and new 30-spline ARB carrier for about $1300.

or you can buy a bolt-in a Ford 8.8 from ECGS for about $1300.

Your call, but I'd never sink $1300 into a D35.....
I love the idea of a c-clip eliminator, but I really don't want to put a locker in a Dana 35.
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Old 01-09-2014, 12:49 PM   #4
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I love the idea of a c-clip eliminator, but I really don't want to put a locker in a Dana 35.
the c-clips & shafts are the first weak link in the D35. the kit that fixes this uses 30-spline shafts and requires swapping to a 30-spline ARB (stock is 27-spline).

If you're not trying to fixing the problem, what are you trying to accomplish?

Why not just save your money for the axle swap, drive the D35c until it blows up, even source another complete D35c in an emergency if you have to. They're basically free....people can't even give them away around here.
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Old 01-09-2014, 12:57 PM   #5
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the c-clips & shafts are the first weak link in the D35. the kit that fixes this uses 30-spline shafts and requires swapping to a 30-spline ARB (stock is 27-spline).

If you're not trying to fixing the problem, what are you trying to accomplish?

Why not just save your money for the axle swap, drive the D35c until it blows up, even source another complete D35c in an emergency if you have to. They're basically free....people can't even give them away around here.
Im stationed in Europe and there isn't many Jeeps around here.
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Old 01-09-2014, 01:02 PM   #6
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Im stationed in Europe and there isn't many Jeeps around here.
how about Ford Explorer's?
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Old 01-09-2014, 01:12 PM   #7
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how about Ford Explorer's?
Nope. This place is filled with Fiat's...
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Old 01-09-2014, 01:18 PM   #8
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Stick with 33's or below, and since you don't go off road much there is not a big rush for doing much to the axle anyways. As has been said (with 33's or smaller) save your money until something happens.

I spent 13 years in Germany and know your pain, however there are some 4x4 clubs around , and you would be suprised at the ammount of parts that are available.
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Old 01-09-2014, 02:45 PM   #9
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When I bought my jeep, the previous owner had already installed ARB's on both ends. This left me in a bit of a quandary since the weak spider gears had been addressed by the ARB & air lockers ain't cheap. That just left the axles... and since I already had an ARB, I couldn't entertain the idea of a "super 35".

I have never had any intention of going beyond 33" tires, but I did want some extra insurance. Unfortunately, Superior went out of business and that was the only C-clip eliminator kit I was really interested in purchasing. But before their remaining stock disappeared completely I did manage to get some of their Discovery series 27 spline (stock sized) c-clip axles.

I did piles of research on what to do about that rear axle, given my plans for the vehicle. Through my research I found that there were no (reliably) documented cases of the Superior 27 spline CCE axles breaking under 33" tires. Furthermore, the axles I purchased are made of the same material, and they don't actually break at the c-clip (located at the very end of the axle). I decided that the small investment was worth it & I wheel with confidence knowing that the weak points in my D35 have been addressed sufficiently for my needs. I would prefer the added confidence knowing I won't lose a wheel if an axle breaks... but can't have it all on my budget.

BTW, my TJ is also an automatic which is known for being a bit softer on axles.

Cliffs: You can make a D35 strong enough to be reliable with 33" tires, but if some of the more expensive work hasn't been done already by someone else then don't bother.
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Old 01-09-2014, 04:02 PM   #10
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Stick with 33's and run stock shafts, upgrade if you feel like it. I had great results with one of my previous jeeps on 33's with stock axles. I wheeled it hard and never broke once!! I was very proud of it. If you want too google 30 spline upgrades for a d35, realistically you can run 35's on a d35 however not very reliable with the 30 spline upgrade... Heck, i got 35's on a d35 atm ( 27 spline )but i am using it until it breaks then upgrading, not sure whether 8.8 will be going in the rear or d44 or just a upgraded axle kit. Money and availability will be my choosing factor. But if you are not hardcore into it, run 33's and keep it stock i bet you won't break a axle. 35's on the otherhand could cause issues, thats one heavy strain on those lil 27 splines.
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Old 01-09-2014, 08:39 PM   #11
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A super 35 kit will allow you to run 35" tires with a full locker with no problems. I'm not sure what some people above are worried about... 30 spline chromoly shafts are fine for 35's.

A Dana 35 is a crap shoot on 33's. Some like mine last years with no problems and some snap them giving it too much gas from a stop. Your call but most are fine as long as you are gentle.

I looked for a few months before finding a used Dana 44 that needed paint and bearings and simply restored it in my garage. Total cost was probably around $425.

If you live in an area where jeep parts are hard to come by and don't have the experience to fabricate a ford 8.8 or similar, I would either get the super 35 kit and have that installed or stay gentle on 33's.
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Old 01-09-2014, 10:40 PM   #12
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I was also in a similar position as you OP. Got the turd and needed some insurance. When it comes down to it, it is still a turd unfortunately.

Complete Ford 8.8" Rear Axle Assembly Jeep TJ Ready to Bolt In Axle Swap

An option as discussed before is an 8.8 swap. Depending what you want I added the adapter flange, a diff cover ( they're supposed to be really thin ), regeared to 4.56 for 33s, brand new brakes and ebrake cables. Still uses stock shafts and everything but still supposed to be more durable and gives you the option of upgrading in the future. Came out to be $1645. For the amount of money you try putting into a d35 I would just save and swap.
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Old 01-09-2014, 11:53 PM   #13
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I was also in a similar position as you OP. Got the turd and needed some insurance. When it comes down to it, it is still a turd unfortunately.

Complete Ford 8.8" Rear Axle Assembly Jeep TJ Ready to Bolt In Axle Swap

An option as discussed before is an 8.8 swap. Depending what you want I added the adapter flange, a diff cover ( they're supposed to be really thin ), regeared to 4.56 for 33s, brand new brakes and ebrake cables. Still uses stock shafts and everything but still supposed to be more durable and gives you the option of upgrading in the future. Came out to be $1645. For the amount of money you try putting into a d35 I would just save and swap.
He's in Europe. I can't even imagine shipping costs for an axle across seas.
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Old 01-10-2014, 01:41 AM   #14
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Thanks for the help guys. I plan on upgrading when I get back to the states to a Dana 60, but until then I will be stuck with this Dana 35. I wish I could find a Super 35 for sale but I can't seem to find it anywhere.
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Old 01-10-2014, 02:56 AM   #15
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Thanks for the help guys. I plan on upgrading when I get back to the states to a Dana 60, but until then I will be stuck with this Dana 35. I wish I could find a Super 35 for sale but I can't seem to find it anywhere.
You can't find any company that'll ship you a super 35 kit? I'd keep searching surely someone would ship one your way.
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Old 01-10-2014, 06:08 AM   #16
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You can't find any company that'll ship you a super 35 kit? I'd keep searching surely someone would ship one your way.
I keep reading that the company went under.
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Old 01-10-2014, 08:02 AM   #17
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Stick with 33's and run stock shafts, upgrade if you feel like it. I had great results with one of my previous jeeps on 33's with stock axles. I wheeled it hard and never broke once!! I was very proud of it. If you want too google 30 spline upgrades for a d35, realistically you can run 35's on a d35 however not very reliable with the 30 spline upgrade... Heck, i got 35's on a d35 atm ( 27 spline )but i am using it until it breaks then upgrading, not sure whether 8.8 will be going in the rear or d44 or just a upgraded axle kit. Money and availability will be my choosing factor. But if you are not hardcore into it, run 33's and keep it stock i bet you won't break a axle. 35's on the otherhand could cause issues, thats one heavy strain on those lil 27 splines.
I meant you can run 35 inch tires on a dana 35 with 30 spline upgrade... and 33's without the upgrade. My bad for the confusion.

With a quick google search i found this site
http://www.summitracing.com/search/p...ne-quantity/30
they have full kits there too i think
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Old 01-11-2014, 03:21 AM   #18
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So no one can recommend a specific Dana 35 Axle shaft kit that is stronger than the rest?
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Old 01-11-2014, 03:25 AM   #19
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Apparently nobody wants to polish a turd these days.
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Old 01-11-2014, 03:36 AM   #20
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I know im probably going to take some heat for this but what the heck are you guys doing with your rigs that you are all so worried about snapping axles? ive hopped my mostly stock yj over logs and up some pretty good trails, but ive never felt like i was in danger of snapping anything
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Old 01-11-2014, 06:49 AM   #21
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I know im probably going to take some heat for this but what the heck are you guys doing with your rigs that you are all so worried about snapping axles? ive hopped my mostly stock yj over logs and up some pretty good trails, but ive never felt like i was in danger of snapping anything
some people snap their D35c axles pulling out of their pavement driveway....on anything ranging from 30s-35s.

in fact, there's an entire website dedicated to broken D35's:
http://www.billhughes.com/dana35c/

Also, there was a "One Car Too Far" episode on Discovery channel, where they broken a D35c in a TJ trying to get off a mountain...the terrain was not that all difficult, and the tires weren't all that big.

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Old 01-11-2014, 07:04 AM   #22
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so i just read into it more and it seems that lockers have alot to do with it? as well as just the torque required to get your wheels turning? so i guess its not suprising that with my stock yj even wheeling it to the limits of traction and taking it to it's very limited full articulation i have never had a problem
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Old 01-11-2014, 07:23 AM   #23
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so i just read into it more and it seems that lockers have alot to do with it? as well as just the torque required to get your wheels turning? so i guess its not suprising that with my stock yj even wheeling it to the limits of traction and taking it to it's very limited full articulation i have never had a problem
like I said before, some people can break a bone stock D35c pulling out of their driveway. no lockers, no slipping, stock tires, slow speeds, no traction problems...just backing out and bang. other people will run a D35c with 35's, and bounce it up rocks violently without a problem for years.
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Old 01-11-2014, 08:08 AM   #24
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wow when u said about the driveway thing i figured u meant with 35's or something!
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Old 01-11-2014, 10:20 AM   #25
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I am in the same situation. My plan is to eventually run and 8.8 when money allows. For now I'm running Alloy USA chromo 27 spline shafts on 35" Baja MTZ's and no lockers. The tires are just about done and new MTR's are next. I have the 4.0L 6 cyl. with a 3 spd. auto. While my brother had the Jeep he went and geared the D30 and D35 to Yukon 4.56's because he got it done much cheaper than what most people pay. I have been going to Paragon Park(now closed) and Rausch Creek since 2005 with this Jeep and never once had an issue.
Keep in mind I wheel gently and don't try to tackle obstacles I know I can't do or drive with a heavy foot. Having an auto transmission helps but that's what I wanted anyway. I still carry my old shafts with me as spares when I wheel though, just in case. I also believe in being properly geared help tremendously with the stress on the shafts.
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Old 01-11-2014, 10:25 AM   #26
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like I said before, some people can break a bone stock D35c pulling out of their driveway. no lockers, no slipping, stock tires, slow speeds, no traction problems...just backing out and bang. other people will run a D35c with 35's, and bounce it up rocks violently without a problem for years.
this is oh so true!
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Old 01-11-2014, 02:40 PM   #27
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The PO of my jeep put on 35's and since buying it two years back, I've drove it like the beast she is. I assume that my Dana 35 (non-polished turd) will break eventually. I want to buy a spare set of axles's so I won't have to strap a log in the wheel well to slide out of the trail. No need for a locker since I have a lead foot...
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Old 01-11-2014, 03:15 PM   #28
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The PO of my jeep put on 35's and since buying it two years back, I've drove it like the beast she is. I assume that my Dana 35 (non-polished turd) will break eventually. I want to buy a spare set of axles's so I won't have to strap a log in the wheel well to slide out of the trail. No need for a locker since I have a lead foot...
Remember with the spare shafts you will need all tools and oil to take off the diff cover the remove the c-clip to install the new shaft.

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