WHAT IS SO BAD .....

shafts are small, ring gear is small, bearings are small. shafts can be upgraded, but basically a waste 8.8 is a good swap. if you want shafts PM me I can give you a good price on some upgraded ones, but money would be better spent on an 8.8.
 
Can it be fixed?
Depends.
What are you planning on doing with it? Driving it? It's fine.
Small lift, some wheeling? Just fine.
lift to handle 33s? With some common sense and careful use of the stupid pedal when wheeling it will last you. Don't lock it, don't try and get over stuff with wheel spin and it will be fine.

So what are your plans? How much lift are you running? You can do a super35 etc etc, but it's "polishing a turd"
I think you are better off going with an 8.8 or a d44 (from a tj) etc.
 
5.5 RE 33"s Uwharrie also dd I know i will need to regear but dont want to waste time and money on dana 35 if not going to stay together . But when wheeling i"m not going to be stupid either. If I drive to Uharrie I have to drive home
 
5.5 might be a bit much lift for just 33s.
Not sure if you've already done the long arms etc etc.
But that's really tall. But if you're going that big, I think hitting up cperry to do you up an 88 or buying a bolt in 44 somewhere then getting cperry to do your front gears to match would be smart.
If you have already done the re 5.5 then I'd go 35" tires at least.

For 33s, I'd look more towards the 3.5" springs or 4.5 at the highest.
Good luck.
 
Why 5.5.... 33"s will tuck better plus 5.5 extreme duty not longarm . I"m also running Bushwacker flares . 33"s got at good price plus concern about dana 35 with 35"s.
 
Sorry, ignore my comment about the lift.
For some reason, when I clicked your profile, I SWORE I saw 01 TJ.
I suck.
XJ's take more lift to get to 33s.
To be honest, i'd probably run the 35 for a while. (I ran mine for ~3.5 years with 33s no issues. Just was a little "careful" when wheeling)
 
Just make sure the first time you ever change a shaft, it isn't on the trail. Shafts never break on flat, stable ground. You want to be familiar with the task before you have to do it in less than desirable conditions.;) Don't ask me how I know this.

BTW, I personally think the 35 is a turd.
 
Just some first hand experience on my current rig. 1990 XJ 4.5 Rusty's coils in front and 4.5 leafs with 2" shackles. 33x14 boggers on 15x10's w/ 3.75 bs. D30 front w/ 95 and up abs shafts and welded D35 rear. Anyone who has seen me wheel knows that I don't give a crap about breaking this thing. Have yet to break the D35 even with alot of wheel spin. Blew apart one D30 when the u-joint let go trying to pull somone uphill in reverse. Since I installed the 95 and up shafts I have had no problems. I get pretty stupid with mine and until I blow my axles up I will keep running them. No need to fix it when it aint broke. With 4.5 in the front I have a very slight amount of rub at extreme flex. BTW I do not have front fenders. With the 6.5 in the rear I have no rub at all.
 
you might try an 8.25.

Before spending money on the 35, I would recommend trying to source an 8.25 out of a newer cherokee to handle the 33's.

The 8.25 came in 27 and 29 spline, with the 29 spline being the one you want (found in '96 & newer cherokees without abs. It would bolt directly in rather than requiring fab in the case of the 8.8. It should hold up to 33's without a problem. The only drawbacks are that 4.56 is the deepest gearset available for the axle and the locker selection is not as plentiful as for say a dana 44.
 
Just so no one misunderstands my previous post. I would not suggest building a D35. I was just putting my personal experiences out there. If youre looking to do a swap I would go with a 8.8 if you're wanting to stay around the stock width or swap in a 44 & 9 out of a old Ford and go fullwidth. I wouldn't run anymore than 33's on a D35.
 
Since it is an XJ then the logical thing to do is get an 8.8 or a 44 from an XJ. Both can be had in 3.55 and only a little cash required to change the spring mounts on the 8.8.
 
I have an 8.25 in boone at Hcore. I will take 125 bucks for it. Dont remember the gearing.I swapped in a 8.8. The 8.25 only has 60xxx miles on it. Pm if interested.
 
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