Topic: Dana 35 Axle Kits

[95 Lowbuck]

There seems to be alot of companies offering after market axle kits for the Dana 35c.
Randy's Ring & Pinion, Super 35 Kit, DTW, and Rieder Racing.
all claim to have axles Dia. sizes as big as a Dana 44 with 30 splines.
I realize I will still have a "C-clip" axle but so is the 8.8 .
I have also heard the Dana 35 axle tube size is about the same as the new Dana 44.
The small Ring Gear is the only thing that is weak.
With these kits running from $700-800, with a Detroit Locker, axles,
bearings, shims, and studs, it sounds cheaper than a axle swap.
Does anyone have any experience with these kits?

[upnorthbacon]

I don't have any experience with those kits, but I can tell you what I've been told on several forums.  Most people I talk to say to just do an axle swap before you spend the money on a "super" kit.  I have several friends who run 35" tires on stock 35 and 30 axles with no problems.  We do mostly mud and sand so the tires will usually spin before they will get enough traction to snap an axle.  None of them run lockers because it would most likely start blowing axles immediately with 35's.  My friend has a factory 2.5 w/stock axles and is running 37" iroks.  He beats on them pretty good and has not blown an axle to date, but again he said there's no way he would put a locker in.  I've heard a lot of stories about guys running "super" kits in the 35 and blowing them out when rock crawling.  Again I don't have any experience with those kits and it's just second hand knowledge, but I'm guessing most guys will tell you to do the swap.

[Jeffy]

There seems to be alot of companies offering after market axle kits for the Dana 35c.
Randy's Ring & Pinion, Super 35 Kit, DTW, and Rieder Racing.
all claim to have axles Dia. sizes as big as a Dana 44 with 30 splines.
I realize I will still have a "C-clip" axle but so is the 8.8 .
I have also heard the Dana 35 axle tube size is about the same as the new Dana 44.
The small Ring Gear is the only thing that is weak.
With these kits running from $700-800, with a Detroit Locker, axles,
bearings, shims, and studs, it sounds cheaper than a axle swap.
Does anyone have any experience with these kits?

First off have you decided on the tires yet?  What's the max size you think you'll ever be going to.  If it's under 35" then you could go with a D35 upgrade kit.  Although you still might want to read this.

Lets chear up some things while we're at it.  The Dana 35 has 27 spline 1.13" axle shafts.  The shafts are prone to breaking where the shaft tapers down right before the splines.  Not all Dana 35's have C-clips. (see link above) The ring gear of the Dana 35 has a 7.5" ring gear and the pinion is 1.406".  The housing is 2.64" dia.  A Dana 44, for comparison, has a 8.5" ring gear dia. and a 1.376" Dia. Pinion.  The axle shafts are 1.30" The axle tubes are 2.75" dia.  Only the TJ D44 uses 2.64" Dia axle tubes.

The 8.8" on the other hand has a 8.8" dia ring gear and a 1.626" Dia. Pinion.  The tube dia. is 3.0" on the Explorer and XLT.  The axles do use C-clips and will range from 28 spline to 31 spline.  The 31 spline shafts are 1.31" dia.

Now what it really comes down to is cost and how much strength you wan/need/can afford.  Depending on where you are a 8.8" 31 spline 4.10:1 gears will cost anywhere from $300-900.  An XJ D44 will cost anywhere from $100-700.  Keep in mine that this doesn't take into account the additional cost it will take to rebuild these axles.  Having to regear is always a pain.  Gears cost around $160 and install ktis are around $90 then you have to find someone to install them if you can't DIY.  Any axle will require some cutting and welding.  Setting up perches and shock mounts.  A Detroit will cost around $500.  But then with any new axle you'll get larger brakes.  In the case of the Ford, you can find disc's.  Oh and keep in mind that you'll probably have to have the rear carrier shimmed which will probably cost as much as a gear change.

Although I wouldn't limit myself to just these two axles.  The Ford 9" from a town car will be setup like the 8.8" and have disc's.  Although it will most likely be 28 spline but you can convert them to 31 or 35 spline.  Isuzu Corporate 10 bolt seems to be a new one.  Although you can sometimes find D44's with gears as low as 4.56:1 stock.  Toyota 8" is alother option.  SJ D44/AMC20 or the SJ D44/D44 combo's are also nice.  I've seen these axles go for $600 a pair.  Early Bronco D44/9" is also an option.  Although the 9" is a 28 spline but can be converted.

If you're not doing anything too difficult and sticking with 33's then I'd probably go with aftermarket stock shafts.  This will gain you some strength in the shafts.  Then you can use the old shafts as spares.  Then throw in a locker and call it good.  Need more strength, swap rather then upgrade.

[95 Lowbuck]

I have a 1995 Rio Grande with a stock 4 banger and 5 sp.
I run a 33-10.50 BFG with 4.10 gearing.(soon to be 4.88)
I do not plan to run a bigger tire on account the 4.88 is
the highest gear set you can get for the Dana 30.
I plan to do mostly trail rides with some rock crawling.
A previous reply stated that even with the super kits
they were blowing out the rear ends.
What were they breaking ?

[might4banger]

The other big deal is the overall condition of your axle. You may find some suprises when you open it up...  :shock:

At one time I thought I had a "simple" leak (pinion bearing) the whole race was wallowed out... along with broken spider gears. Might want to pop the top and take a look see before you make a decision. A little RTV and gear oil might save you big coin in the long run.

Just my $ .02

[wrangler387]

I'm going to run a 30 spline dana 35 kit eventually, but i also got a used detroit for a good price. But before i found the 30 spline detroit i was looking into what axle i wanted to swap in.
I'd definately see how cheap you can find some other axles locally, if they are all pretty expensive and you don't want to run larger then a 35" then i say go for the super35. Otherwise do a swap.

[Jeffy]

I plan to do mostly trail rides with some rock crawling.
A previous reply stated that even with the super kits
they were blowing out the rear ends.
What were they breaking ?

With a SUper 35, all you're doing is shifting the likelyhood of a broken part to a different area.  The D35 as a hole is pretty well balanced.  As in no one part is significantly stronger or weaker then the next.  When you beaf up the axle, you still have the weak housing and small Ring and Pinion.  The housings really need to be beafed up.  Superior stopped making their overpriced truss recently too.

[Liljeepz]

Dose any one have any thoughts on http://www.currieenterprises.com/cestore/jeepdana44rearends.aspx
for dana 44s? Its about the best cost i have come acrost for D44, and they sell 44 frount new too!
I want to do a axle swap for both frount and rear, lift kit, airlockers, and tires all at once. been saving for a year, I figured 1 more year and Ill be set, in the time I been looking at both upgraids and swaps, I dont want to set my self up for breaking on the trail, Might as well do it right the first time.

[Jeffy]

Currie makes some decent axles.  One way they cut costs though is to use old axle housings.  They clean them up of course though.

You might want to check Drivetrain Direct.  They sell prebuilt axles too.  All of then are new and in makes cases OEM.  Actually there are a lot of smaller builders out there that aren't too expensive.  At least not as expensive as Dynatech.  In some way's you do get what you pay for but in other way's they're no different then salvaging your own axles and DIY.

Currie does have a good deal on D44's with D30 inner knuckles so they take D30 outers and keep the 5 on 4.5" bolt pattern.

[shotgun]

Jeffy Makes some good points.  While you can do things to make some axles near bulletproof or even better than bulletproof. No axle is bomb proof. With the right multiplication even our under powered 4 bangers can bust up a dana 60.  Build it for how you're going to wheel it and your budget. For some this will be keeping a stock dana 35 with c-clips.  for others it will be the 8.8 which I don't personally like. It's a ford thing, I don't expect you to understand.

My Rig will always be Dana / AMC / Jeep / DC.

[bigbrad_4x4]

While we're on the subject of axles, my buddy offered to sell me a D60 for $600. He says it's got new 4.10 gears, no locker.  What do you guys think about the deal?

[Jeffy]

While we're on the subject of axles, my buddy offered to sell me a D60 for $600. He says it's got new 4.10 gears, no locker.  What do you guys think about the deal?

What's the width?  65-67"  FF or Semi?  30 spline 1.30" shafts or 35 spline 1.5" shafts?  D60's are pigs and you'd want to run 35's as a minimum.  Shave it and you could get the clearance of a D44 though.