My $0.02 summary on the subject of Dana 35 rear axles and if I knew then what I know

[fishgutz]

My $0.02 summary on the subject of Dana 35 rear axles based on my own experience and the many D35 threads I have followed here. What I know now has been learned from knowledgeable people on this board and some very patient people back in NH and MA.
First, I would not have spent $1000 having a Detroit True Track and new 4.10 gears installed in my stock D35. The Dana 35 housing is not strong enough to reliably run anything bigger than 31” tires. The stress of 33’s twisted the axle just enough the shear bolt heads off the locker. The bolts heads just mangled up everything in the diff. If I can find the old pictures I’ll post them.
If 31’s are you ever have planned, fine. But your first trip to Uwharrie will change your “to do list.” If it doesn’t, then you must have been traveling with H2’s.
There are a few affordable rear end upgrades. Ford 8.8 inch is probably the most popular. That is what I have now. Another mechanical master on this board recommends the Ford 9”.
If you score a Ford 8.8” with and LSD, don’t bother with the lunchbox locker. For a less $150 more you can get the Detroit locker and save time. You’ll eventually break the LSD carrier and have to get new locker anyway. When you read that the carrier is the weak link, take it from me, it is. It came out in two big pieces. Luckily the ring and pinion are still in great shape and don’t need to be replaced.
Had I done this from the start, I would have saved about $2000.
As for the front, I still have the Detroit True track I had installed back in 2003. Front upgrades occurred as needed after that. Vacuum diaphragm rust through so I installed Chromo axle shafts with 760X u-joints. When the tie rod ends went, I did a Rugged Ridge HD steering kit and Moog ball joints.
There are some nice Superior Axle/ locker packages that upgrade the front to 30 spline from the 27.
When I break something now, I look for the most affordable Right way of getting back on the road. Not the cheapest way. In my case, “cheap” often turns out to be more expensive.
If I decide I want to go bigger than 35’s that’s a whole other set of considerations and will have to wait until my kids are done with college.

 

[96superflow]

Good info. So in the 8.8 the carrier is the weakest link? So going detroit locker or ox in my rear would be better then throwing a lunchbox locker in it and making it very reliable for 35's.

 

[fishgutz]

Given that my LSD carrier broke with just 33's, I'd suggest learning from my mistake.
The power trax no-slip for the LSD carrier is $490. The Detroit is $625. I paid $700 including shipping. So, my total cost to get the Detroit is over $1200 since I bought both.

 

[Rox&Mud]

Good info. So in the 8.8 the carrier is the weakest link? So going detroit locker or ox in my rear would be better then throwing a lunchbox locker in it and making it very reliable for 35's.

Yes and yes.
I have been running 37x14.5's for years on my 8.8 with a Detroit and 4.88 gears with no issues.

And yes the simple answer on the turdy5 is that it is crap. I blew mine several times with open carrier and 31's. Resolved the issue with the above mentioned 8.8.

 

[fishgutz]

Rox, that is Cool. I was hoping the 35" in the Documentation that came with my Detroit locker was based on an excess of safety margin.
Are you running with the c-clips?
I am considering going to the 36" IROK next time. I've been very happy with the 33" TRXUS MT. 3rd set now. Cutting sheet metal while my YJ is on jack stands to install the Detroit.

 

[Rox&Mud]

Other than tj brackets, wheel spacers and the detroit it is a stock 8.8. I have never even carried spare shafts although thanks to CFC I'm going to pick up a set for both my ZJ and TJ. Oh, BTW, I have a 8.8 in my ZJ too also with detroit. No problems there either but it is on 33's but is a much heaver Jeep.

 

[burrellsjeep]

You should be more than happy with the 8.8 on 36s.

 

[wrangler00]

i run 33s on my open 35 and i havent broke mine yet (knock on wood) i prolly wont go up to a 35 with it but i think its good now but i dont do hardcore extreme rock bashing wide open either but ive been to ure and have had no trouble i prolly shouldnt post this cause now the next time i ride ill bust it but im just saying

 

[Joe J.]

I think the non-lsd carriers are stronger than the lsd carriers, is that true?

anyway, as soon as I fix the 45mph dw in my front end, my plan of attack is and 8.8 with the factory lsd, 4.56 gears and 33's. and up front an open d30 with 4.56.

later, before I get tube fenders and 35's, I plan to truss the 30 and maybe add a locker and chromo's, and If any money left I'll get a selectable locker for the rear. Do the 8.8's need c-clip eliminators and shafts to run those type of lockers? and is this a good plan of attack for someone that can't do all upgrades at the same time?

 

[braxton357]

I think I've seen more 35's break driving on the street than on the trail... Certainly a weak axle all around. Why waste time with the 8.8 though, dana 70's are where it's at.

 

[burrellsjeep]

I think the non-lsd carriers are stronger than the lsd carriers, is that true?
anyway, as soon as I fix the 45mph dw in my front end, my plan of attack is and 8.8 with the factory lsd, 4.56 gears and 33's. and up front an open d30 with 4.56.
later, before I get tube fenders and 35's, I plan to truss the 30 and maybe add a locker and chromo's, and If any money left I'll get a selectable locker for the rear. Do the 8.8's need c-clip eliminators and shafts to run those type of lockers? and is this a good plan of attack for someone that can't do all upgrades at the same time?

The carriers that I have seen fail have been non-ls carrier running a lunch box locker.

Mudder that sounds like a pretty solid plan of attack.

 

[burrellsjeep]

I think I've seen more 35's break driving on the street than on the trail... Certainly a weak axle all around. Why waste time with the 8.8 though, dana 70's are where it's at.

Although I don't want to agree, He has a point. There is allot to be said for just going with tons from the start. As far as cost goes your better off. But if you want to keep the down time short, You swap in an 8.8 and keep wheeling.