dana 35

trex-x-xj

trex-x-xj

Active Member
Joined
Feb 29, 2008
Location
Greensboro NC
hey guys.. i have a 1990 jeep xj with stock dana 35 axles. ive been wanting to upgrade to a dana 44 for a while. but i cant seem to find a set in my price range.. so could anyone give me some advice on how to "beef up" my 35's?
 
Youre front axle is a dana 30, which is doable on those tires, chromoly shafts , maybe a truss. You can find the larger spline 8.25 rear axles out of the later model xj,s for very cheap, probably find one hear in the for sale section.
I cant remember the years that had the 8.25 with the larger spline count, Im sure someone will chime in. If you are not driving like a mad man an 8.25, or ford 8.8, early xj d44 will work for you.
 
Best way to beef up a dana 35? Weld a chain to it and use it for a boat anchor!

8.25 Chrysler at the very least. Will be strong enuff.
Dana 44's for XJ's are great, but usually overpriced.
8.8 Ford best alternative! Very plentiful and not real expensive to build!
 
After 96 or 97 I believe they went from 29 to 31 spline....That being said...Ive got one from a 2000 XJ for sale.
 
I didn't catch the tire size your running but if (like someone else said already) if your not driving like a crazy wild man and keep it reasonalable on tires of 35 or smaller, the D35/D30 will more than hold up while you save up money. its not worth I don't believe for the money to upgrade anything on the 35s and 30s. I've wheeled them for 14years or so and never upgraded, I just weld em and go until something happens even on 39.5s but not recommended to do. run it, drive it moderately and just save your cash is your best bet and if you stay off the rocks, you'll be fine. one thing for sure is you'll love the ground clearance you get from a D35 for whatever tires your running since it is a small carrier so just be easier on it until you can upgrade. good luck and have fun wheeling your xj most of all!!!!! don't be discouraged just cause someone tells you it's a grenade waiting to happen. they are (I believe) just jealous of what they have seen XJ's do with D35s on big tires and won't admit their capability for what it is for better reasons than I care to mention. WHEEL THE CRAP OUT OF IT DUDE, ITS A JEEP!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
 
I was only mildly laughing until here:
88jeepster said:
they are (I believe) just jealous of what they have seen XJ's do with D35s on big tires and won't admit their capability for what it is for better reasons than I care to mention. WHEEL THE CRAP OUT OF IT DUDE, ITS A JEEP!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Click to expand...
Here's the list of things I broke on my D35 on 31's or 32's (all in separate incidents):
Left axleshaft
Lockrite Cross-shaft
ARB carrier case (busted in half)
Open carrier spider gears
4.56 ring and pinion

Then I upgraded...

I am a big fan of the D30 in the front, but the D35 is really not up to torque or weight unless you have a 2.5L, small tires, and no ambition with your right foot.

If you really want to beef it up, buy a Super 35 kit with either Detroit or ARB. That will give you 30 spline axleshafts and a decent locker. Then buy a good truss, put it on, and wheel it till it breaks. Only problem with the 30 spline kits is that you can't just carry stock shafts for spares...
 
well......I beg to differ on 36s and 35s and 39s even wide open in mud, snow and hills where need be but Im starting to think stock gears have something to do with it cause that is the one thing I've never changed is the gears so maybe bigger gears strain them more,............im baffled with xj's breaking D35 on 31s or 32s cause I abused the crap out of some jeeps on 32x11.50s and well it took every bit of it and even 33s I've beat the hell out of em so ....................it leaves me to believe its gotta be the gears.
Also, to the OP, I wouldn't spend a dime on super 35 kit for how much it costs, you could find a 44 easily or at least a 8.25 and have left over for beefing up the front.
 
Just get an 8.8 out a 98+ explorer and you wont spend a lot of money and you will have a very reliable axle. They are disk brakes too. If you like to hit the rocks sometimes and/or you like to get into the throttle then the D35 will leave you hanging for sure one day.
 
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