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Old 02-28-2012, 04:45 PM   #1
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Max tire size for Dana 35

I have a 91 yj and want to upgrade to some bigger tires. I'm thinking 35's or 36's. Will this smooth my gears in a matter of minutes or will I get by on light off roading? I plan on putting a 8.8 in it next winter but just wanted some tire upgrades for the summer and longevity is not a huge factor since it will be replaced in a year. Has anyone done this or whats your thoughts? Thanks in advance for the replies.

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Old 02-28-2012, 05:15 PM   #2
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You can do it, tho, as far as LONGEVITY goes, that could be the moment you pull
out of your Driveway, or it could be a Year. There's NO RYME or REASON when
dealing with a stock Dana 35.

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Old 02-28-2012, 05:22 PM   #3
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Quote:
Originally Posted by CoyoteOn2 View Post
You can do it, tho, as far as LONGEVITY goes, that could be the moment you pull
out of your Driveway, or it could be a Year. There's NO RYME or REASON when
dealing with a stock Dana 35.

By the way, WELCOME to WF.
Very true. I have heard of people having it last for a couple years and some not even last a month. I am wary of the D35 with my 31" tires!
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Old 02-28-2012, 06:26 PM   #4
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You have the right attitude. I would also say I would not count on anything. Basically plan on putting the 8.8 in at any time. Don't set a date for it. Then run her til she pops.

36's are heavy.
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Old 02-28-2012, 06:46 PM   #5
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I ran 31" baja claws with a 3.55 geared d35, buts nervous and tried to avoid letting axle hop on an obstacle! I had a d44 with locker and 4.88's and eventually got 34" ltbs! Them ltbs and locked front and rear were heavan!
I now have a yj with 4.10s, locked up front and lsd back aft ( first jeep was an xj) and still running those 34s
I wouldnt go much bigger than 31s with a d35 and I would never lock one, saw a jeep with a super 35 kit in it break axle like 15 min. Into first run he did after having kit installed
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Old 02-28-2012, 07:05 PM   #6
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Realistically, 31's are the biggest tire that should be on that axle. Yes, others have 32's or 33's on it without issue, but those who do wheel with that size tire often don't let the tires spin at all.

When they slip then suddenly gain traction is when you can snap a shaft.

I broke my original one on the road, doing 55mph around a shallow corner. They can and will break at any time, don't push your luck with tires bigger than 31". The front can handle 35's just fine but over that and it needs attention.
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Old 02-28-2012, 07:13 PM   #7
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33's Open depending on what you plan to do with your Jeep
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Old 02-28-2012, 07:53 PM   #8
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Why are these axles so weak? How did Jeep get away w putting the d35 in so many off road vehicles? If and when I guess my shafts break, I've got 33's and 3.07, can I replace them w better shafts? This is my budget toy.
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Old 02-28-2012, 08:05 PM   #9
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Yes you can get a super35 kit that will allow you to run 35's locked.. Superior Gear and Axle AND Yukon Gear is my two recomendations as to were to purchase it if you were to do so.. Runs between 1k-1400 bucks i believe..

To this day I don't think anyone understands why they put such a weak axle in there Jeeps.. It is very confusing as to trying to figure out what they were thinking
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Old 02-28-2012, 08:19 PM   #10
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Quote:
Originally Posted by chopprr View Post
Why are these axles so weak? How did Jeep get away w putting the d35 in so many off road vehicles? If and when I guess my shafts break, I've got 33's and 3.07, can I replace them w better shafts? This is my budget toy.
If ya break just replace shaft and when you can afford it swap out entire housing/ carrier for a 8.8 or d44

I wouldnt waste me time or money on a super 35 kit, seen to many of them Break too!

There is too much flex ( even when trussed) in a d35
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Old 02-28-2012, 08:44 PM   #11
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Yeah even an S35 kit can break easily. Overly expensive, an 8.8 swap would be less expensive, which is still 2-3x as strong as an S35 kit.
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Old 02-28-2012, 10:20 PM   #12
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I ran 33s for a long time and my buddy's all run 33s locked. They seem to hold up but if you really romp them they go pop lol. Run the bigger tires till you blow it haha or swap now and sell the d35.
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Old 02-28-2012, 10:37 PM   #13
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The Dana 35 isn't as bad as people make it out to be. I have seen people spatter Dana 60's and GM 14 bolts on the same trail I have climbed with a welded Dana 35. Now I am not saying they are the best axle, but it is all in how you wheel. I go slow, and am not ashamed to get the winch out.
I have seen them go "pop", but on my last outing I also saw an 8.8 go "boom" and I pulled him home with my welded Dana 35 on 33's.
Now I have broken a few GM 10 bolts which is the worst axle I have had, and 2 Chrysler 8.25's which people say is an upgrade to a 35. Go figure.
Moral of the story.....don't pound on it too hard, if you think it "may" break be prepared. I have a rear axle waiting for mine, I just need the gears for the front to match
Good luck.
P.S. I do not recommend welding the 35 if you drive on the road much, but I do it on mine every time.
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Old 02-28-2012, 10:51 PM   #14
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How much is too much on road driving for a welded 35? How does handle? What can I expect if I do weld it?
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Old 02-29-2012, 07:33 AM   #15
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I wouldn't recommend welding the 35 to anyone that depends on their Jeep as a daily driver. If it is anything close to a daily driver I would seriously look into other options.
I weld mine and I know it is advised against beacuse like Xpress has had a near stock rig with the 35 break on the highway. I may go to town and get gas, and beer once in a while, but I don't use mine as a primary vehicle. With that said the Dana 35's are hit and miss I suppose. I have not broke one, but I have seen them broke, as wels as almost every axle and ring gear under the sun.
It will handle funny when you turn tight, and will eat-up your rear tires if you do much on the pavement. I think the weakest thing on a 35 is the axle tubes them selves, but others say it is the axles, and ring gear. I have warped axle tubes, but never broke anything else on a Dana35
I wouldn't spend a bunch of money on it as the 8.8 is a real good choice and upgrade. (still a c-clip axle though)
Good luck
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Old 02-29-2012, 10:00 AM   #16
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Thanks for the info I think I will run with my current 33's and see what happens this summer, then when it blows I can do a full drive train upgrade instead of patching factory parts.
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Old 02-29-2012, 11:22 PM   #17
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Ok noob question. Where do I look for said 8.8? Under what vehicles?
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Old 02-29-2012, 11:43 PM   #18
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IIRC 95-01 Ford explorers fpor disc and 95 and under for drum.
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Old 03-02-2012, 07:38 AM   #19
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dana 35

Alloy usa has some 4140 chromolys in 27 spline for the dana 35. Weld the tubes and truss it! But i would not go above a 35'' tire.
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Old 03-02-2012, 10:15 AM   #20
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The Dana 35 started life as a AMC axle. So blame AMC.
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Old 04-16-2012, 12:01 AM   #21
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i was worried about putting 33" tires on my Tj but when i went to Camp Coffs jeep action in Australia there were alot of people with 35" tires on theirs which is strange cause Australians are scared of Big tires usually so to see 35" tires on a TJ was very surprising but im worried about putting them on my Tj
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Old 04-16-2012, 07:40 AM   #22
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IIRC Some tj's came with d44 rears. Thats an advantage for sure.

I am not against running 33-35's on a upgraded d35 but for way less money you get a great axle with the 8.8. You can still upgrade that too if you want.
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Old 04-17-2012, 10:42 AM   #23
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well i am hoping to put dana 44 in the front and amc in the rear because of a old Cherokee in the shed that's diffs are very well so hopefully that will work much better
the rubicon Tj's had dana 44s just like the new ones
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Old 04-17-2012, 11:00 AM   #24
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Quote:
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well i am hoping to put dana 44 in the front and amc in the rear because of a old Cherokee in the shed that's diffs are very well so hopefully that will work much better
the rubicon Tj's had dana 44s just like the new ones
Some Sahara's also had the D44 in the rear, it was also standard on any model LJ.
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Old 04-17-2012, 11:16 AM   #25
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Quote:
Originally Posted by UnIuckychucky View Post
well i am hoping to put dana 44 in the front and amc in the rear because of a old Cherokee in the shed that's diffs are very well so hopefully that will work much better
the rubicon Tj's had dana 44s just like the new ones
Im not exactly sure what you are trying to say here...but ill just put in my 2 cents.

There is really no need to look into a D44 for the front of a TJ unless you need to go with gears that are deeper than 4.88. The front D44s that will bolt in are essentially the same thing as the D30 that is there from the factory.

As far as an "AMC" axle...I dont know what you are talking about since the more popular amc is the amc20 for CJs (which is way too narrow for a TJ and the bolt pattern is different.) If you are gonna go thru the hassle of fabbing up another axle to fit a TJ, you might as well go with the 8.8. They are cheap, strong, and plentiful.
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Old 04-17-2012, 01:58 PM   #26
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Can you swap out your 4.10's into the 8.8?
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Old 04-17-2012, 02:04 PM   #27
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got two yj's running 33's on a D35 with a detroit locker for 12 years now without issue....drive with some sense and it will be fine
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Old 04-17-2012, 02:09 PM   #28
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Can you swap out your 4.10's into the 8.8?
Just find an 8.8 with 4.10s already...some came from the factory with them already
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Old 04-17-2012, 03:04 PM   #29
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Just find an 8.8 with 4.10s already...some came from the factory with them already
You want a D2 coded axle. That has 4.10s and limited slip. Found in Explorers/moutaineers/etc from 1996 to 2002 (i think, may be later as well).

Here's a list of the Explorer Door codes and their corresponding axle gears/configs:

43 Open 3.08
41 Open 3.27
42 Open 4.10
46 Open 3.73
45 Open 3.55
D4 Limited Slip 3.73
D2 Limited Slip 4.10
L73 Limited Slip 3.73
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Old 04-17-2012, 03:41 PM   #30
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Quote:
Originally Posted by denisbaldwin

You want a D2 coded axle. That has 4.10s and limited slip. Found in Explorers/moutaineers/etc from 1996 to 2002 (i think, may be later as well).

Here's a list of the Explorer Door codes and their corresponding axle gears/configs:

43 Open 3.08
41 Open 3.27
42 Open 4.10
46 Open 3.73
45 Open 3.55
D4 Limited Slip 3.73
D2 Limited Slip 4.10
L73 Limited Slip 3.73
Don't get the limited slip though if there is any possibility you will put a lunchbox locker in. The limited slip carrier really limits your options to the "powertrax no slip"

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