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Old 08-10-2006, 11:50 AM   #1
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Question Upgrading Axles

Right now my '03 4.0 is stock. I want to get 33's, 12.5 wide tires and lift it 4 inches. After reading several threads in the forum, I seen that many people upgrade their axles to handle the bigger tires. I don't have a rubicon, so I am pretty sure I have a 30 / 35 setup. Upgrading the entire axles looks pretty pricy. However, I saw there is a superior axle kit. The product description says that it upgrades the splines from 27 to 30 (the same as a dana 44)? What does this mean? Is it still the same diameter as a stock 35, only they managed to cut more splines in it. Or is it actually a wider diameter? How is it superior? I would like the ability to add lockers in the future.

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Old 08-10-2006, 12:16 PM   #2
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The upgraded, super 35c, is larger in diameter, and stronger. There are two main suppliers; Superior axles, USA Alloy. I know that USA alloy has a 10 yr. warranty on theirs. Here is a picture of the standard vs. super.


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Old 08-10-2006, 02:11 PM   #3
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I see,... So it is a larger diameter... Is the super's diameter the same as a stock 44? Ok, lets say that I go with the super 35 axles, when I decide to purchase a locker, what size would I get? A dana 44 /30 spline? Even though it is a dana 35 housing? Also I saw that there is a super 30 axle with 30 splines. Any Idea what the diameter is on the super 30? None of the websites Iv'e looked at mention the diameter only the splines. Sorry for the barrage of questions.
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Old 08-10-2006, 02:35 PM   #4
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Dont worry about your front dana 30 with 33's you wont have any problems with it. As for your dana 35 i wouldnt put any money into it.... your better off finding a dana 44 off an xj or finding a ford 8.8 out of an explorer. I think there are 2 problems with the super 35 kit the first is if you do happen to break one of the shafts the only way to replace it [the shaft] is to buy another kit. The second problem it only replaces the shafts and the carrier [with the locker that comes with it] everything else is still dana 35. In the end its better not to put any money into your dana 35.
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Old 08-10-2006, 02:40 PM   #5
coilovers are damn flexy
 
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I would just run the original axle until it breaks, then replace it. You have to change the diff when putting in the superior, to accept the 30 spline.

Here is a good write up on this upgrade; http://www.jpmagazine.com/techarticl...lding_dana_35/

This article lists the pro's and con's.

I know some people don't care for JPMagazine, but this is a good write up. I don't subscribe, just found the article on-line.
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Old 08-10-2006, 07:21 PM   #6
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The super 35 kits is a good choice if you don't plan to go over 33's, Don't mind having a "odd ball axle" Meaning... if you brake one on the trail the local parts store or jeep dealer can't help you. Now on the mostly positive side, my buddy has run his on his 99 with the detroit locker and 33's, and expect for the detroit going south and the hell it was getting one for it, it has done well for him.
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Old 08-10-2006, 08:51 PM   #7
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i would run it till it busts and then replace it...the front 30 should be fine but you will probably want to upgrade the rear...and yeah the superior kit is an upgrade that upgrades the spline 27 axleshafts to stronger 30 axleshafts that are yes the same as the 44...so you get stronger axleshafts which is a big weak point
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Old 08-11-2006, 05:19 PM   #8
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You should really find out what rear axle you have first before you decide what to do. Easiest way. Check the drain plug. D35 will have a plastic plug. D44 will have a metal one. The D35 is more of an oval shape also.
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Old 08-11-2006, 05:20 PM   #9
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ya and the 44 has a squarish metal plug
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Old 08-11-2006, 07:15 PM   #10
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I have a rubber looking plug on the rear differential. So I guess it is a dana 35. How do I tell what ratio gears I have? I saw a metal tag on the differential but I couldn't make any sense of the numbers.
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Old 08-11-2006, 10:28 PM   #11
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I think its the last 3 numbers on the second line with your 4.0 you should have 3.07's or 3.55's
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Old 08-11-2006, 10:47 PM   #12
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thanks Nick...i tried to check mine today and i of course found the tag but also couldn't make sense of the numbers...i was about to check a site that tells me how the tag works but ya helped me out...i'll see if it is the last 3 numbers on the second line tomorow morning...i think it will be either 3.07's like you said but not 3.55...if its not 3.07's it will probably be 3.73's
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Old 08-11-2006, 11:32 PM   #13
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It might be the first 3 numbers on the second actually the 3 numbers should kinda stand alone by which i mean there should be a space inbetween the gear ratio numbers and the other numbers. The first time i ever looked at mine i had to clean the tag off a lot before i could read all the numbers they are usually easy to spot after the tag is cleaned off.
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Old 08-14-2006, 02:22 PM   #14
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Another direction to think about might be to go to a junk yard and see if you can find an Unlimited rear axle since they come with a dana44 and swap out the d35. If I remember correctly, it's a bolt on swap.
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Old 08-14-2006, 03:11 PM   #15
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ya it should be bolt on since it goes right on the unlimited tj...Nick, ya i checked and there was a space between the numbers...but i didn't have to clean it cause there isn't a lot of miles on it...

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