Originally Posted by iino27ii
Well to be honest a stock Dana 44 on a jeep isn't much stronger than a 35C, the only main difference is the C clip on the 35 c, if chrysler had made the C clip then forged the metal it would be alot stronger, but they did it backwards....
The TJ's Dana 44 axle is significantly (!) stronger than the Dana 35c. The Dana 44's larger diameter ring gear is significantly stronger and the Dana 44's axle shafts are 30 spline vs. the Dana 35c's smaller diameter and break-prone 27 spline shafts. There is a night and day difference in the strengths of the Dana 35c vs. the Dana 44. For up to 35" tires, people hammer on even locked Dana 44 axles without problem... me included. Two different TJs, both locked front and rear with 35" tires, never a problem with either of its Dana 44 axles. Do I do trails tough enough to break axles & axle shafts? Yep, I broke my Dana 30 twice and grenaded my first TJ's OE Dana 35c early in the game.
And FYI, the Dana 35c's c-clip doesn't actually weaken its shafts... the shafts are the same strength whether it's a pre-C-clip design or post-C-Clip design. The c-clip itself is completely protected behind the carrier and isn't subjected to forces applied to the axle. The only problem the c-clip causes is if the axle shaft snaps, the outboard parts of the break will slide out of the axle housing taking the wheel with it.