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Old 01-25-2020, 03:33 PM
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D35 full float Drive flanges 5x4.5

Sorry im not a big poster and im doing this off a phone so bear with me. I bought a dana 35 off a guy 12 years ago for 75 bucks. Dude was a crawler, went to moab every year. It had a lunch box locker, gears, and a warn full float kit. 6 years ago i blew the ring and pinion out of my factory 35. In a pinch i threw that full float in, i switch out the 4:56 gear not in favor for but to match the 3:07 that was in the front. Anywho my jeep isnt a hardcore wheeler. Its a chore whore farm jeep. I drag trees out of timbers for fire wood, check the fences plow my lane and yank other jeepers out of the unmaintained roads in the area and flat out injoy the engineering and simplicity of a TJ. threw the years i found that a lunch box locker and crappy warn hublocks were not a good combo. Fast forward to last year. I ripped everything off my Tj frome the frame down and started over. IT NEEDED IT ! I installed a hp 30 up front along with a bunch of suspenion mods to increase travel and driveability. I also took on the back end with the same agression.

As to the drive flanges. The axle shafts on a dana 35 are 1/100th of a inch larger than that of a dana 30. They are the same 27 spline count. I simply pressed apart a unit bearing from the front 30.

Know with the full float kit you have spanners that tighten down your rear wheel bearings just like a older cone style setup on A front axle.

Now i dont have a picture of the next step bit i stacked weld beads all the way out to the end of the spindle twice over AND TOOK MY TIME TO NOT WARP IT. this was so i could take it to the local machine shop and have them conter bore it to clear the spaner nuts.

Once the machining was done i just did some measuring and cut off the drive flange and capped it so it had some room for a spring to hold the axle shaft in place.

I didnt stop there cus i took the opportunity to swap out the old drums for a ZJ disk setup. I had to hog put the ZJ mounting bracket preaty good for the hub to clear but it can happen.

I got about 2000 miles on this setup now. Been off road with it, 75 mph down the highway. Draging trees out of the timber. Pulling cords of wood home. And chained up plowing snow. It works grear and have had zero problems unlike the hublockers that warn had on them.

If i didnt already have this axle half built and the conections to do this cheap i wouldn't of wasted time on the 35.but its been preaty durable for my 33"s and 3:73 gears it has in it now. Some day it might get the one tons off my old f350 but probably not any time soon. Hope this helps for anyone that has that full float kit and wants to get away from the hublockers and dosent want to switch wheel bolt patterns or throw money at granading hublockers all the time.

I do have alot more pics of this project along with a ton of my front hp30 setup

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Old 01-25-2020, 10:48 PM
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What it had originally, and the dana 30 wheel bearing on the shaft
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Old 01-25-2020, 10:54 PM
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And the disk brake conversion
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Old 01-25-2020, 10:58 PM
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And the final product
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