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-   -   Upgrading a Dana 35? (http://www.wranglerforum.com/f282/upgrading-a-dana-35-a-119220.html)

FISHN4X4 10-24-2011 12:24 AM

Upgrading a Dana 35?
 
Is there any way to beef up the Dana 35 rear? I heard its a weak rear end, and I plan on doing mild off roading with my Jeep, and I plan on doing a 4 inch suspension lift soon and eventually 33 inch tires with that. It makes me a little nervous to do this if the rear end is weak. So I was wondering if theres any way to make it stronger so it holds up to more. I dont really want to spend a ton of money getting a Dana 44 to put in it, I'd rather just try to make what I have better. Any help would be appreciated

jkaufman_95 10-24-2011 12:26 AM

You can do a super 35 kit. Which is very strong

Molonlabemike 10-24-2011 12:27 AM

You can get chromo axles but your just gonna polish a turd. Save the $600 to build it and save for a 44 or 8.8.

erickpl 10-24-2011 08:07 AM

For those that say the turd can't be polished and it is cheaper to replace an axle, please post links to axles in good shape that will go right in w/o welding or repairing. I always see posts like "it's cheaper to do D44 swap/ 8.8 install" but never see documented pricing. Finding a cheap axle isn't always easy and 8.8 often require welding and mods to fit - more resources to be spent that never get factored in for some reason.

The Super 35 kit is a seriously viable option for those that don't have the knowledge or skills to do a swap. I did a cost analysis when I did mine and compared a D44, 8.8, or a D35 upgrade. Given my resources (money, knowledge, time), the S35 upgrade was the most feasible way to go.

Now I don't pound the crap out of my TJ like some do. My solution is not the skinny pedal when stuck. Gotta drive smarter than the rocks you're going over. My 35 upgrade has been solid reliable for the 5 years I've had it (and it IS locked with an ARB). My only wish was disc brakes vs the drums I have, but I can live with that.

I also regeared during this time, so the labor differences for installation were minimal (I didn't get double dinged for those labor costs.

Yes, the Dana 35 can be problematic - if you drive in such a manner as to put it at risk. But for those that realize the limitations of their rigs, an upgraded D35 can be a viable option. Would I have preferred a D44 or 8.8? Sure, but the downtime for my rig, storage space while I had things apart, my lack of welding tools, and extra parts I'd have to buy to make either work (think driveshafts, spring perches, etc) just made those solutions impractical for ME.

I don't have the kind of luck to have a cheap D44 with driveshaft or TJ-ready 8.8 fall in my lap for a stupid-low price like some here seem to have.

chux72vette 10-24-2011 08:54 AM

No one explained what a Super 35 build is to the OP and am curious also.

erickpl 10-24-2011 10:42 AM

A super 35 kit has the following:

- Upgraded shafts that goes in the axle tubes. 30 spline vs the standard 27 and made from a stronger alloy.
- Locker (either selectable or automatic depending on choice). Now you CAN choose no locker, but you would only have 27 spline shafts vs 30 but it would be the stronger alloy.
- Other stuff

Here is a kit on Northridge 4x4 (man, they've gone up in price!)

Northridge4x4 Jeep Parts: Rear Axles

ou812 10-24-2011 10:46 AM

Im just finding out that a s35 kit with the detroit locker plus 5 speed doesnt play well together.Its said that a 5 speed with a detriot auto locker in the rear,makes the 5 speed hard to shift thru gears.

I'd go with the arb locker option,and just deal with air,or look into just the s35 axle kit and use a diffrent locker

Cons_Table 10-24-2011 11:03 AM

Quote:

Originally Posted by ou812 (Post 1686498)
Im just finding out that a s35 kit with the detroit locker plus 5 speed doesnt play well together.Its said that a 5 speed with a detriot auto locker in the rear,makes the 5 speed hard to shift thru gears.

I'd go with the arb locker option,and just deal with air,or look into just the s35 axle kit and use a diffrent locker

Ive never heard anyone say that a detroit makes it hard to shift a 5 speed. Im not even sure why the rear end would change how your transmission shifts. I could be wrong, so anyone with some knowledge on this, enlighten us.

As far as running a super 35...you can only run the lockers that they provide because the super 35 changes your spline count, so unless you can find other lockers that are 30 spline dana 35 lockers, youve only got a few options.

FISHN4X4 10-24-2011 11:19 PM

thanks for the info guys, im gonna have to figure out the route I want to go

svtyone 10-24-2011 11:54 PM

Quote:

Originally Posted by jkaufman_95 (Post 1685804)
You can do a super 35 kit. Which is very strong

while the new axles are extremlt tough unfortunatly its till a dana 35. the case is weak. i twisted my diff housing almost 180 degrees then the axle finally gave but its not worth the money for the super kit. find a junk yard with a few rubi 44 axles and call it good. maybe the best 1500-2000 youll ever spend.you might be able to talk the guy into including the controls for the lockers.

MikeMTJ 10-25-2011 12:02 AM

The super 35 kit is a great kit from what I've seen. One guys that I used to wheel with would hammer on his on the rocks, and he couldn't break it. He now runs it in the same TJ with a 318 under the hood. He has yet to break it.

I think a trussed D35 with the super 35 kit would be great. The axle housings are cut from the same stock as a TJ D44 anyways.

jkaufman_95 10-25-2011 12:38 AM

Quote:

Originally Posted by svtyone
while the new axles are extremlt tough unfortunatly its till a dana 35. the case is weak. i twisted my diff housing almost 180 degrees then the axle finally gave but its not worth the money for the super kit. find a junk yard with a few rubi 44 axles and call it good. maybe the best 1500-2000 youll ever spend.you might be able to talk the guy into including the controls for the lockers.

Like mike said. The tubes are the exact same as a d44

FISHN4X4 10-25-2011 07:58 AM

I think when I do it i'm gonna go with the super 35 kit, I'll buy it with a locker too. Seems like the cost effective route. I'm really not doing anything too nuts offroad mainly I'm gonna have it out on the beach, and sometimes on some of the trails around the area that arent too intense

solman 10-25-2011 08:51 AM

I still say go 8.8. The super 35 kit costs over $1000, then add the labor of installation, $200 - $400 depending on where you go. And you still have a d35 that I would not trust with anything over 33" tires.

For the same price You could have a ready to bolt in 8.8. (Yes I said ready to bolt in.) I have been building 8.8s for TJs for a little while now, In fact I just shipped one to a forum member 2 weeks ago. $1200 shipped and that included labor for a gear change and master install kit.
And you would still have your old dana 35 laying around that you could probably get $200 for. So now you have $1000 or less invested into a rear that will handle 37s all day long with disk brakes and huge aftermarket support.

solman 10-25-2011 08:53 AM

Heres a few pics of some of my 8.8s
http://i1194.photobucket.com/albums/...4/IMG_0559.jpg
http://i1194.photobucket.com/albums/...4/IMG_0585.jpg
http://i1194.photobucket.com/albums/...4/IMG_0591.jpg
http://i1194.photobucket.com/albums/...4/IMG_0597.jpg

erickpl 10-25-2011 08:59 AM

Clean shop. :)

If I grenade my upgraded D35, I may be giving you a shoutout! :)

solman 10-25-2011 09:01 AM

No problem and thank you. The one I shipped out 2 weeks ago went to Mobile Alabama.

FISHN4X4 10-25-2011 02:35 PM

Wow thats a nice looking rear. Does it come with a locker? if so what kind? And as far as swapping out rears goes how difficult is it? I probably wouldnt be able to do it myself... always seem to mess something up

Molonlabemike 10-25-2011 03:06 PM

For those with the skills a built 8.8 can be done for under $1500 or leas and that would be all the beef most would need. I plan to beat on my jeep so I want the best axle and cause I am poor it must be cost effective.

solman 10-25-2011 03:20 PM

Quote:

Originally Posted by FISHN4X4 (Post 1690083)
Wow thats a nice looking rear. Does it come with a locker? if so what kind? And as far as swapping out rears goes how difficult is it? I probably wouldnt be able to do it myself... always seem to mess something up

Thanks, No locker but it does have a limited slip diff. The 8.8 is the most cost effective axle upgrade even if you have to pay someone to weld it for you. I can buy 8.8s at the local junkyards all day long for $300, The bracket kit is $250, the only other things you need are, Driveshaft adapter ($35), e-brake cables ($60) and the labor for cutting off the old brackets and welding on the new brackets ($250) and you are ready to bolt it in.

I am picking up another 8.8 on Thursday and should have it together sometime next week. It will have 3.73 gears and a limited slip. No rotors or calipers. I will be selling it for $750

BillG.OTD 10-25-2011 04:29 PM

Super 35 with Locker
 
Quote:

Originally Posted by FISHN4X4 (Post 1689238)
I think when I do it i'm gonna go with the super 35 kit, I'll buy it with a locker too. Seems like the cost effective route. I'm really not doing anything too nuts offroad mainly I'm gonna have it out on the beach, and sometimes on some of the trails around the area that arent too intense

I think that you can find some good package deals on the upgraded axles and a locker kit as was posted. I just got mine through 4 wheel parts and they had a 1/2 off labor special during the recent sales event. I went with the super 35 (EV35LK) and an Eaton E locker and paid about $1600 installed, but if you do the work you could take $500 off that. I paid for the install because the project is well over my mechanical comfort zone. Superior also sells their axle kits in combination with lockers.

BlackedOutYJ 10-25-2011 05:02 PM

Quote:

Originally Posted by erickpl
For those that say the turd can't be polished and it is cheaper to replace an axle, please post links to axles in good shape that will go right in w/o welding or repairing. I always see posts like "it's cheaper to do D44 swap/ 8.8 install" but never see documented pricing. Finding a cheap axle isn't always easy and 8.8 often require welding and mods to fit - more resources to be spent that never get factored in for some reason.

The Super 35 kit is a seriously viable option for those that don't have the knowledge or skills to do a swap. I did a cost analysis when I did mine and compared a D44, 8.8, or a D35 upgrade. Given my resources (money, knowledge, time), the S35 upgrade was the most feasible way to go.

Now I don't pound the crap out of my TJ like some do. My solution is not the skinny pedal when stuck. Gotta drive smarter than the rocks you're going over. My 35 upgrade has been solid reliable for the 5 years I've had it (and it IS locked with an ARB). My only wish was disc brakes vs the drums I have, but I can live with that.

I also regeared during this time, so the labor differences for installation were minimal (I didn't get double dinged for those labor costs.

Yes, the Dana 35 can be problematic - if you drive in such a manner as to put it at risk. But for those that realize the limitations of their rigs, an upgraded D35 can be a viable option. Would I have preferred a D44 or 8.8? Sure, but the downtime for my rig, storage space while I had things apart, my lack of welding tools, and extra parts I'd have to buy to make either work (think driveshafts, spring perches, etc) just made those solutions impractical for ME.

I don't have the kind of luck to have a cheap D44 with driveshaft or TJ-ready 8.8 fall in my lap for a stupid-low price like some here seem to have.

I got $500 in my 8.8 swap, that's rebuilding the whole damn thing from a new carrier to all new seals. I spent some money I shouldn't have on mine as well, and I've parted out my old boat anchor and made $150 off it so far and still have axel shafts. So all in all $350 in it. I wish I kept my receipts to show your ass. Lol

IslandTJ 10-25-2011 05:10 PM

Quote:

Originally Posted by erickpl (Post 1686213)
For those that say the turd can't be polished and it is cheaper to replace an axle, please post links to axles in good shape that will go right in w/o welding or repairing. I always see posts like "it's cheaper to do D44 swap/ 8.8 install" but never see documented pricing. Finding a cheap axle isn't always easy and 8.8 often require welding and mods to fit - more resources to be spent that never get factored in for some reason.

The Super 35 kit is a seriously viable option for those that don't have the knowledge or skills to do a swap. I did a cost analysis when I did mine and compared a D44, 8.8, or a D35 upgrade. Given my resources (money, knowledge, time), the S35 upgrade was the most feasible way to go.

Now I don't pound the crap out of my TJ like some do. My solution is not the skinny pedal when stuck. Gotta drive smarter than the rocks you're going over. My 35 upgrade has been solid reliable for the 5 years I've had it (and it IS locked with an ARB). My only wish was disc brakes vs the drums I have, but I can live with that.

I also regeared during this time, so the labor differences for installation were minimal (I didn't get double dinged for those labor costs.

Yes, the Dana 35 can be problematic - if you drive in such a manner as to put it at risk. But for those that realize the limitations of their rigs, an upgraded D35 can be a viable option. Would I have preferred a D44 or 8.8? Sure, but the downtime for my rig, storage space while I had things apart, my lack of welding tools, and extra parts I'd have to buy to make either work (think driveshafts, spring perches, etc) just made those solutions impractical for ME.

I don't have the kind of luck to have a cheap D44 with driveshaft or TJ-ready 8.8 fall in my lap for a stupid-low price like some here seem to have.

Well stated :thumb:.

OP, there's also the option of Superior's C-Clip Eliminator kit, for strengthening the D35, if you don't want a locker.

SUPERIOR AXLE & GEAR - products new home - Superior\'s Super Eliminator(TM) C-Clip Eliminator Axle Kit for Jeep Wrangler Wit

solman 10-25-2011 06:40 PM

Quote:

Originally Posted by BlackedOutYJ (Post 1690415)
I got $500 in my 8.8 swap, that's rebuilding the whole damn thing from a new carrier to all new seals. I spent some money I shouldn't have on mine as well, and I've parted out my old boat anchor and made $150 off it so far and still have axel shafts. So all in all $350 in it. I wish I kept my receipts to show your ass. Lol

The 8.8 is a much easier swap into a yj though. You can get away with not buying an aftermarket bracket kit since you have no control arms or spring perches.

Skyhawk32 10-25-2011 07:29 PM

What are y'all pulling these 8.8s out of?

BlackedOutYJ 10-25-2011 08:54 PM

Quote:

Originally Posted by Skyhawk32
What are y'all pulling these 8.8s out of?

Explorer's, mountaineers

IndyJeepMan 10-25-2011 09:04 PM

95-01 explorers come with disk brakes and 31 spline axle shafts.

Solman, you pay $300 for junkyard axles? You need to move your business here! I get them all day long for $130 :)

Currently have $350 in mine with about another $1000 to go.

erickpl 10-26-2011 07:53 AM

Quote:

Originally Posted by BlackedOutYJ (Post 1690415)
I got $500 in my 8.8 swap, that's rebuilding the whole damn thing from a new carrier to all new seals. I spent some money I shouldn't have on mine as well, and I've parted out my old boat anchor and made $150 off it so far and still have axel shafts. So all in all $350 in it. I wish I kept my receipts to show your ass. Lol

You can show my ass, but I don't think it'll see it - it doesn't have eyes and I don't have my head up it. :D

People talk about snagging the 8.8's for $500 and down, but around here, that price is not realistic. I sure wish it was - it would have changed the path I went with my rear axle. The fact that I have a 2.5L engine also persuaded me to go with an upgrade to my D35 vs a complete swap. It doesn't generate enough torque to break it! :D

Some people can find great deals on the gears and salvage yards and those are the ones that always seem to post how cheap it is. Even if I DO find a deal on an 8.8, shipping still has to be factored in.

My only point is that upgrading a D35 can be done to make it a decent axle. Sure it isn't as strong as an 8.8 or D44, but it IS an option.

BlackedOutYJ 10-26-2011 08:11 AM

I paid $180 for mine which had a open carrier, I then got a like brand new ford arrive for $25. I had to shop around for a few weeks but I found a great deal. People was all over the place with prices on one. I had a junk yard local to me want $500 and my Dana 35 for a 8.8 (ya I let them know how insane they were). I just kept shopping and found a great deal

Got 4 Lo 11-22-2011 08:22 PM

Quote:

Originally Posted by erickpl (Post 1692585)
You can show my ass, but I don't think it'll see it - it doesn't have eyes and I don't have my head up it. :D

People talk about snagging the 8.8's for $500 and down, but around here, that price is not realistic. I sure wish it was - it would have changed the path I went with my rear axle. The fact that I have a 2.5L engine also persuaded me to go with an upgrade to my D35 vs a complete swap. It doesn't generate enough torque to break it! :D

Some people can find great deals on the gears and salvage yards and those are the ones that always seem to post how cheap it is. Even if I DO find a deal on an 8.8, shipping still has to be factored in.

My only point is that upgrading a D35 can be done to make it a decent axle. Sure it isn't as strong as an 8.8 or D44, but it IS an option.

not to be off topic but do you think i could run 33's and a auto locker in the stock D35 rear with the 2.5L with some mild wheeling mostly DD?


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