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Old 03-19-2011, 03:55 PM   #1
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So i destroyed my D35...

I got my 2000 TJ in aug of 2009. it came with a 3" body lift to clear 33" tires. It was fine untill last thursday there was some vibration while i was on the highway. I pulled over but didn't see anything and the rear driveshaft didnt have any excess play in it. getting off the highway i heard a loud bang as I took it out of gear. Again i pulled over and still didnt see anything. I went to my friends house and it was makeing grinding noises. We diagnosed it as the rear dif but I had work the next day so i carefully drove it home then to work then back to my friends house (near my work) and we eventualy decided it was over our heads so i took it to the mechanic. Today he called and told me that when he opend the cover chunks of teeth fell out and that my ring gear had lost teeth and the teeth had damaged the carrier.

Long story short: The D35 in my daily driver is shot and i need it fixed ASAP.

should I:
1: get the parts to fix the D35
2: try to get a replacement D35
3: try to get a D44 replacement

It is mostly just a daily driver but i would like to take it off road occasionaly. It has 33" tires and 3.73 gears so if i do get a D44 i would have to regear it or the front but I could put that off and just not use 4 high.

what would be the most bang for my buck and most affordible option?

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Old 03-19-2011, 04:04 PM   #2
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I guess it would depend on how accessible a new D44 or a replacement D35 axle would be.

If it where me, and I could afford to have it down for a couple days I'd see if I could get a D44. If I couldn't afford it being down I'd replace the bad gears with new ones if the center section wasn't thrashed. That would put me back on the road as fast as possible.
Good Luck!

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Old 03-19-2011, 04:33 PM   #3
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How close are you to this guy http://www.wranglerforum.com/f14/dan...ml#post1126353

I would try to run down a D44 rear witch will have 3.73 gearing.. 33's also means you should look into 4.56's or 4.88's gearing IMO
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Old 03-19-2011, 05:08 PM   #4
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I live in PA so that D35 wouldn't work
I found a D44 w/ 3.73 gears and an open diff from a 02 with 75.92k miles on it for $1375.
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Old 03-19-2011, 05:40 PM   #5
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If your from PA check out this one.
TJ LJ Dana 44&30 - 3.73 w/40K Miles


If I had the extra $ I would be all over it. It will save you from having to re-gear as well if your front axle is not already 3.73.
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Old 03-19-2011, 05:49 PM   #6
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Go with the d44
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Old 03-19-2011, 06:31 PM   #7
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That pair looks good. What do you think i could get for the D30?
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Old 04-04-2011, 12:17 AM   #8
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The 35 is good as a boat anchor, go for the 44 or a 60.
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Old 04-04-2011, 08:02 AM   #9
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The 35 is good as a boat anchor, go for the 44 or a 60.
lol, 60.
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Old 04-04-2011, 03:11 PM   #10
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44 or an 8.8 not worth throwing away good money on another time bomb!
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Old 04-04-2011, 03:24 PM   #11
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One thing to keep in mind is that it would only cost $600 at the very most to completely rebuild your existing D35c. That includes a new ring & pinion gear, bearings, shims, and carrier. That is what an honest 4x4 shop would charge. A dishonest shop or a dealership might charge $1200 to $2000 which is of course a complete ripoff based on their assumption that few people would not believe that much $$$ is unrealistic for what may seem like a lot of damage to the unitiated.

So while replacing the axle with a Dana 44 or Ford 8.8 may be a sexier way to go, that is only needed if you are running big tires, locker, and do really tough trails. If your Jeep is more of a daily driver with only mild offroading on the weekends, I'd just get it repaired for the $500-600 any honest competent shop can do it for.

Even if it also needs spider years it wouldn't much more than that since most 4x4 shops have old but still good spider gears in their junk boxes they pulled out of axles during various upgrades. Many shops would throw them in for free if you need them and if they have them laying around as many do. Spider gears do not need to be set up like the ring & pinion gears do so there would be NO additional labor needed to install replacement spider gears if the old spider gears are trashed. Since you say you need a new carrier, the spider gears need to be inserted in the same way whether they are new or old.
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Old 04-04-2011, 04:07 PM   #12
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I live in PA so that D35 wouldn't work
I found a D44 w/ 3.73 gears and an open diff from a 02 with 75.92k miles on it for $1375.
Thats WAY to much. I payed for a D44 in PA with the same specs as that one for $600.
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Old 04-04-2011, 04:16 PM   #13
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Get a 44 I've had both I like my d44 better.
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Old 04-04-2011, 04:24 PM   #14
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8.8...cheaper, stronger, more available
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Old 04-04-2011, 04:41 PM   #15
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8.8...cheaper ,,,
Not unless he's able to fabricate and weld on his own. If he has to pay someone else to weld plus buy or fabricate the required brackets, it's nowhere near cheaper than repairing what he has. He could buy a used Dana 44 out of a TJ that would have same 3.73 gearing for less than it would cost him to get an 8.8 ready to bolt into his TJ.

Those who claim used 8.8 axles are cheaper are leaving out a lot of costs a non-fabricator will have to pay on top of the axle's cost to get it ready to bolt in.
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Old 04-04-2011, 04:44 PM   #16
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I did about suggest a 8.8. But Jerry has a point
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Old 04-04-2011, 05:42 PM   #17
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D44 and 8.8 come to about the same price after you purchase the brackets and have them welded on. I was looking at both myself and decided to go with the D44 cause it bolts right in with no hassle.

If you can find a cheap 8.8 with brackets already on, i'd go that way though.
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Old 04-04-2011, 05:46 PM   #18
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A TJ D44 ready to be bolted into place can be found for $600. How do you buy an 8.8, buy the brackets which typically sell for $400 for the set (like from M.O.R.E. or RE), and then pay a welder to jig them up and weld them in place for $600 total?
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Old 04-04-2011, 05:48 PM   #19
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Complete Ford 8.8" Rear Axle Assembly Jeep TJ Ready to Bolt In Axle Swap

Best solution if you can't fabricate. Very affordable, and pretty much bolts in. You would have to get an adapter for your drive shaft, which should cost $30.

Also, most shops will weld on brackets for cheap if they are honest people. Buddy of mind had his welded on for $50.

D44s are to expensive for my taste.
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Old 04-04-2011, 05:51 PM   #20
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A TJ D44 ready to be bolted into place can be found for $600. How do you buy an 8.8, buy the brackets which typically sell for $400 for the set (like from M.O.R.E. or RE), and then pay a welder to jig them up and weld them in place for $600 total?
I typically find the brackets for $200.

TJ Wrangler Rear Axle Bracket Kit [Axle Kit-TJ] - $199.00 : Mad 4 Wheel Drive
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Old 04-04-2011, 05:59 PM   #21
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Good luck finding a D44, but 8.8 are everywhere, or if u cannot fabricate check out eastcoastgearsupply.com, i got my 8.8 shipped for $1,010, it will be even cheaper if u get 3.73 gears.Really its only a few hundred $$ more than buying one and welding the brackets urself,which i was gonna do, but with the yards wanting $400 for the 8.8(in my area, dont know why the want so much for them here) plus the cost of brackets and the time and effort i forked up a few hundred more and go one ready to go in.

Cheapest i found 8.8 brackets are $245 from ironrockoffroad.com
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Old 04-04-2011, 06:09 PM   #22
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You can get an 8.8 from ecgs for $675.00 ready to bolt in! You have 33 inch tires. This is the breaking point for the dana 35 . It will let you down again if you don't upgrade it! So as I said before you can waist six to eight hundred on rebuilding a time bomb, or just call east coast gear and get the 8.8 for the same money ready to bolt right in!
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Old 04-04-2011, 06:42 PM   #23
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That's a lot cheaper than they used to be. Both M.O.R.E. and RE sold their TJ bracket kits for $400 but it appears M.O.R.E. is now down to $330. Jeep TJ axle swap for Ford 8.8
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Old 04-04-2011, 06:49 PM   #24
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You can get an 8.8 from ecgs for $675.00 ready to bolt in! You have 33 inch tires. This is the breaking point for the dana 35 . It will let you down again if you don't upgrade it! So as I said before you can waist six to eight hundred on rebuilding a time bomb, or just call east coast gear and get the 8.8 for the same money ready to bolt right in!
Thats the base price...u have to pay for gears(even stock ratios) plus other little things,and the $200 handling fee.Mine came out to be $1,010 with 4.10's, higher gears r cheaper.
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Old 04-04-2011, 07:10 PM   #25
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Still better spent money then the 35 .
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Old 04-04-2011, 07:41 PM   #26
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Upgrade or replace the D35. So much of this D44 vs D35 is just like "which is better Mercury or Volvo Power?" I have a D35 in my Jeep, but I've had both Mercury and Volvo Power (in boats) Merc props will work on a Volvo drive (8.8 analogy) but you need to modify/adapt something. Volvo props won't work on Merc drives. I ended up going with a Volvo prop because it did what I wanted, and was in my acceptable price range.

Ask yourself, what is my budget, and my application, do some research and go from there.

I've heard lots of good things about the Super35 upgrade kits, on this forum and others, and respected off road mags. Thats probably what I would do....

Good Luck!

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