Topic: Another dana 35 question

[jfrabat]

Yes, D35's do break; I've seen it happen, but I've also watched 44's and 60's break, too. 

I think that pretty much sums it all up; Bottom line is D35's r not the best axle out there, and we are aware of this.  But it is not as bad s it is made to be some times.

[Bounty Hunter]

Heck, I gently used it on one of our more difficult trail complexes Sunday by running tailgunner behind a Built Jeep (King of the Hammers entrant).  I made it thru a mud hole he didn't; of course, he made it thru some other places easily that required a lot of skinny pedal by me.

Would that have been Alan?

I too ran my original d35 pretty hard for years, with a welded diff and 32" or 33" TSL's.  No problems.

[melbill]

I have read a bit about welding the axle tubes. Can anyone explain how to do this, how much extra strength will this give me, and is it worth while?

[jfrabat]

I have read a bit about welding the axle tubes. Can anyone explain how to do this, how much extra strength will this give me, and is it worth while?

I thought the D35 WAS welded; it was the 8.8 that needed welding...  Could be wrong, though.

[Jeffy]

I thought the D35 WAS welded; it was the 8.8 that needed welding...  Could be wrong, though.

Most axles have the tubes welded through the rosette.  D35's don't have the problem of axle tubes rotating like the 8.8 though.  I don't think it will increase the strength any but is more of a preventive maintenance sort of thing.

[melbill]

OK that makes sense I wasn't sure if it was a D 35 thing or something else. Thanks for all the info.

[Castr8r]

BH- Yup

[Bounty Hunter]

I was on the first TRJC 4x4 Safari run after it replaced the JJUSA event, great event.  Would like to do it again sometime.

[BarneyJeep]

i have seen a d35 pumpkin rotate on the tubes, iirc the d35 tubes are just pressed in without welds. like the OP said, if you just trail ride and have already regeared....put a truss on and carry spare shafts, i would look into the c-clip eliminator kit simply because it replaces your axle shafts with the alloy one and in the event that you do break a shaft it will prevent the wheel, brake drum, and whats left of the shaft from walking out of your axle housing possibly causing more damage to bearings and seals.

[TahoeYJ]

I'm running 4:88's and haven't had an issue so far with mine. Granted I still haven't gone wheelin' since regearing my front axle, I've been in plenty of sticky situations running 2WD with 33's and 35's. Had to use the skinny pedal much more than I'd of liked and just prayed the D35 wouldn't go. Spiders, R&P, and shafts all look good, splines and everything. I came acoss an Aussie locker for it but turned out to be for a 94+ and it didn't fit, maybe it was a sign not to lock my D35 

I've got a Ford 9" that's been sitting taking up space for over a year, I just haven't spent the dough on it to build it up. I know a guy with a 28 spline detroit for $200, I'm almost thinking about just taking it... It'd be nice to have 31 spline Mosers (those things are BEEFY!) but for $200, it's hard to pass up!

[FourbangerYJ]

I'm running 4:88's and haven't had an issue so far with mine. Granted I still haven't gone wheelin' since regearing my front axle, I've been in plenty of sticky situations running 2WD with 33's and 35's. Had to use the skinny pedal much more than I'd of liked and just prayed the D35 wouldn't go. Spiders, R&P, and shafts all look good, splines and everything. I came acoss an Aussie locker for it but turned out to be for a 94+ and it didn't fit, maybe it was a sign not to lock my D35 

I've got a Ford 9" that's been sitting taking up space for over a year, I just haven't spent the dough on it to build it up. I know a guy with a 28 spline detroit for $200, I'm almost thinking about just taking it... It'd be nice to have 31 spline Mosers (those things are BEEFY!) but for $200, it's hard to pass up!

Hold out for a 31 spline locker. They can be had fairly cheap used. Keep an eye on E-bay. Alot of time the NASCAR guys sell off their Detroits for fairly cheap.  The 28 spline is just about the same strenth as the 27 spline D35.

[Bounty Hunter]

i have seen a d35 pumpkin rotate on the tubes, iirc the d35 tubes are just pressed in without welds.

They're plug welded like every other Dana axle, they wouldn't stay otherwise.

The d35 is not a turd if you know its limitations and plan accordingly.  Of course I wouldn't put much money into one, like the Super kit or any c-clip eliminator.  You can set up an 8.8 for the same or less money.

[jcsanders79]

The d35 is not a turd if you know its limitations and plan accordingly.  Of course I wouldn't put much money into one, like the Super kit or any c-clip eliminator.  You can set up an 8.8 for the same or less money.

This was my point earlier.  In TN we got mud and rocks and thats when I've seen the D-35 have the most problems.  On a large muddy rock.  Like mentioned before any axle can break, hell anything on a Jeep can break.  The biggest pain about the D-35 is you HAVE to fix it trialside to get out.

[TahoeYJ]

This was my point earlier.  In TN we got mud and rocks and thats when I've seen the D-35 have the most problems.  On a large muddy rock.  Like mentioned before any axle can break, hell anything on a Jeep can break.  The biggest pain about the D-35 is you HAVE to fix it trialside to get out.

You can get away with a ghetto quick fix by doing the good ol' tree-limb-strapped-around-the-wheel-to-keep-it-from-walking-out trick 

[jcsanders79]

You can get away with a ghetto quick fix by doing the good ol' tree-limb-strapped-around-the-wheel-to-keep-it-from-walking-out trick 

That can work,  depending on how difficult the trail is....  Not to mention it usually causes a lot more damage and you'll end up spending more $.