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UPGRADING THE 35 ?s

3K views 36 replies 15 participants last post by  Rob5589 
#1 ·
So, I'm gonna be re-gearing my stock 30 & 35 to 4.56 Gears. My 97 TJ has

I6 engine
5 Speed Manuel
DPG ultimate lift
32"s
Stock drive shafts n brakes
3.73 Gears
Limited slip rear(rear axle taken from a newer jeep)
Rock sliders & Aftermarket Bumpers
I mostly drive my TJ fast in Ocotillo washes and hills, I push my Jeep fairly hard RPM wise. I'm surprised I haven't broken anything yet, this jeep also takes to and from my destinations. I don't do a whole lot of slow crawling and don't plan to make that my main objective but I do want to be able to tackle the tougher obstacles not the extreme ones. I've done mid level trails in Big Bear and a couple difficult ones(also turned away from some too) lol. It's not a DD or a complete toy but I bought it for adventures with my sons, going camping and making passengers giddy inside. But sometimes I take it around town a crawl the local mall.

I don't want to go looking for a 44 or 8.8 so that's not in the cards. I'm upgrading to Revolution Gear n axles 4.56 gears, I want to upgrade to their 30 spline shafts, do I need new carriers? Can I get away with just the rears since the 30 is supposed to be tougher?

If I add a selectable locker will I need a carrier for the rear or just the front if left open? I thought about a lunch box locker in the front but I've read its tougher to turn while 4x is engaged and I drive hard in 4hi down washes so not so sure that's a good idea.

What's the best options for what I'm doin? Funds are limited to maybe 2k and I'll add more later when I make some more sales at work, my brother in law will be doing install and is experienced in re-gearing but has never installed a ARB locker but does know about them, thinks it's not out of his league, just has to go slower. He's a off-road enthusiast, allighns 4x4s other shops can't and has 20 years mechanics experience (owns his own shop) but it's no 4x4 only shop.

Need some help so I know what to order
Thanks
 
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#2 ·
Check with Revolution in regards to whether the axles will fit the carriers. The No Slip works well in the front 30. I ran one in an XJ with 33's through the Rubicon and Fordyce without a problem.
The ARB is an easy install. You will need to drill and tap the diff housing for the airline, again not a big deal. You could do Truetacs since you aren't a dedicated rock crawler.

Nice rifle in your avatar. They are doing all they can to take them from us. Make your voice heard about the recent laws thrust upon us.
 
#5 ·
If you are going to spend money on it, I would do the 30 spline axles and 30 spline locker along with your new gear set and bearings. (Obviously 30 spline axles won't work with the stock 27 spline carrier.)

ARB® Dana 35 Air Locker - ARB #RD125 Diff Locker non C-clip 30 Spline (3.54 & up)
Since im only locking the rear do i need to mess with the front besides gears so i can reuse the carrier. I dont see myself gjoing bigger than 33's. I would like 35's but then it wont fit in the garage
 
#10 ·
Lunchbox in the rear. Sell the LSD. Spartan is a good one. I have lockrite. Reason is, weight shifts to the rear when you're headed uphill. That's where the piece of mind of a full carrier/lunchbox auto locker comes in handy. Selectables are for more serious pursuits (crawling, mud, etc.)

Honestly, the front can be left open if you're just rooting around the desert. If you do go autolocker up front, i can tell you that off-road, and even at speed, the locker will become open when you turn. It's only locked when you're going straight (sometimes it takes a second lol, and you'll know when it happens). Once you learn how an autolocker works, it's really predictable. Manual makes it more of an interactive experience than an auto, but works well in either.

I wouldn't do much more than upgraded gears and shafts in the rear. The axle's reliability is only as strong as your right pedal. Which it sounds like you lay in to.

Sounds like you need a jeep with coliovers lol
 
#11 ·
Sounds like you need a jeep with coliovers lol[/QUOTE]

I really want a Razor but i need a truck to tow it and somewhere to store it..

Im very impressed with DPG's Ultimate kit the way its handled offroad so far, i do my best to avoid the woop dee doos. I smash on the skinny pedal which is why im hesitant on the auto lockers.
 
#14 ·
Sounds like you need a jeep with coliovers lol
I really want a Razor but i need a truck to tow it and somewhere to store it..

Im very impressed with DPG's Ultimate kit the way its handled offroad so far, i do my best to avoid the woop dee doos. I smash on the skinny pedal which is why im hesitant on the auto lockers.[/QUOTE]

Think about it this way. With selectables on, you theoretically have more of a problem turning in 4wd. At least with auto-lockers you will unlock with a turn and the right amount of pedal. With selectables, you have to develop a new skill of when to turn them on and off...

Owners of both will say, "It's not a big deal to the above scenarios". They are both right. Get the lockers. Just know if you want to spend $1500, $2000, $2500 or $3000. Keep in mind that Detroit lockers approach selectables in price because they're super strong. And btw, broken axles can shred any locker.
 
#12 ·
I am no expert in Jeeps just got into them, I live in south FL so I dont see any serious rock crawling, but I do have extensive experience in GM performance and building drivetrains for racing.

Basically the way I see it. If you have 2 grand. The selectable lockers and gears are way out of your price range. Everybody locally charges $500+ for gears install per axle hoising.

Go with the lunch box style locker in the front. I drove a rig with one up front their is a noticeable difference in steering but its not that bad. A decent set of tires with a front locker and some skill you will be fine.

I personally ordered a powertrax lock rite for my front and a no slip for my rear. Both of those together put me just below 800$. I will be installing them so no added cost there. Those with my warn powerplant...
There is no where I cant go
 
#16 ·
If keeping the d35 rear is the only option then I'd definitely go with a 30 spline locker with revolution 30 spline chromoly shafts. I'm pretty sure they offer a super 35 kit with either a Detroit locker or an ARB. If you mainly do desert then the Detroit would be the better option as the ARB is more for crawling IMO. As for the front d30, you can use the stock carrier for 4.56s I believe (don't quote me on that, I'm sure someone will chime in on this) and leaving it open is fine as well. You can leave the stock shafts of its open too but make sure you carry an extra set or at least spare u-joints when off road because you never know if you'll break the stockers. The super 35 is also strong enough for 35s on the tj by the way.
 
#28 ·
Nobody is trying to sell anybody weak D44's here.
The point was that the OP has better options than sinking $$$ into a D35.


For you guys that really want to stand behind the 35, power to you.
When yours goes "pop", you can have mine for free.
It's been sitting since my swap and so far I haven't been able to give it away.
 
#31 ·
I actually had a machinist repair it. It's been back in the jeep for a week now
 

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#32 ·
Ok I'm int he same posistion as the OP except I have a D30 front and D44 rear with 3.73 gears currently. I bought the jeep used and it has 35's. I live in a slightly mountainous area and don't have the power when climbing. If I gear up to 4.88 will this be good enough for me and be a little adventurous? Can anyone verify that I can use my current carriers? I believe I can because I'm on the higher side of the breaks. Do I need to be concerned about my axles and I will be driving it regularly at highway speeds. Please advise on my gear choice of 4.88 from G/2.
 
#33 ·
4.88 will help you immensely. On and off road. Highway speeds will be attained much easier. Even if your carrier was below the break, they make thick gears for just that purpose. Btw I believe 4.88 is the limit you can go in a d30.
 
#34 ·
Laggy, thanks for the info! I'm purposely going to 4.88 as I see that in my search that was the largest I could find for a D30 and I don't have the means to axle swap. Do you happen to know if the G/2 kit below has a "thick" gear? The one ring on the right does appear to be thicker. Thanks for your help, this will allow me to re-gear and not have to buy new carriers or be tempted (have to talk my wife into) buying lockers!

http://https://www.quadratec.com/products/52466_001X_PG.htm
 
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