Super 35 kit?

[CoronaKJ]

I have a new to me 95yj 4.0 5speed with a dana 35 rear end. I am planning on regearing to 4.11 and putting in a OX locker and thought I would just save up and have an complete rear end built upgrading to a dana 44 rear end. The guy at the shop mentioned they could do a super 35 kit that would be just as good, and a little cheaper. I am currently and planning on only running 33" tires, but maybe would like the option to go to 35's later on. I also want to pull a small trailer like something from AT. Please advise or share some knowledge, thanks:smiley_drive:

 

[Overland]

just so you know where i'm coming from, i have a 92yj, 2.5lt, 4:88's, dana 60 with ARB rear and Alloy USA super 30 HP with ARB front on 37" IROKS.

i ran 34's and 35's on the stock dana 35 rear end for about a year with no issues. but i have the 2.5ltr and i am light footed and the diff was open. i never broke but i was careful....got tired of that so went to the D-60.

in my opinion the stock D-35 will be ok with 33's if your careful since you have the 4.0 but once you lock it up and go to 35's it will be on borrowed time. the super 35 kit wont be alot cheaper than an axle upgrade. look for an 8.8 out of a Ford explorer. some came with 4:10 gears and disc brakes. i can get them locally at the wrecker for $150.00. they are the correct bolt pattern and width.

 

[BIGdaddy]

yup. I agree with the above. the dana 35 is fine for normal up to 33" tire use. no lockers, no rockcrawling, easy on the go-pedal.

I'd go ahead and get the d44, rather than spending money on the d35, but don't think you can't go wheeling with it. Run whatcha brung till it breaks.

 

[Donsfast]

I ran a D35 with 4:56s and an ARB, 4:1 tcase for years on 33"s with no issues at all. I did many extreme trails for years with no complaints but think you should consider something else if you have the money to spend. A D35 will get the job done but is weaker than either a 44 or a Ford 8.8 which is an easy swap and can include disc brakes. I would opt for the 8.8 (out of Explorer)over a 44 hands down for strength compared to price and easy of swap.

 

[Waytec]

I would suggest the 44 or the 8.8 but people that have them now know that they are wanted; they want big money for them. I have found people including wrecking yards wanting up to $2000 for an 8.8.
If you are set on keeping your D35 and up grading it, the super 35 is a good kit and I would also truss the diff for towing, they tend to flex with a trailer on them. The D35 will handle 33s with no issue 35s is when issues start to creep up.
I would also suggest look at 4.88 gears instead of 4.10 they would be better of towing

 

[Xjaddiction]

No, don't waste ur time and money on a dana 35. Switch it out for the 29 spline 8.25 out of a XJ (small) some late 96 to 2001 cherokees, or the 8.8, or go with grand Wagoneer axles front and rear Dana 44's. Leaf sprung axles are easy to throw under there.

Try running the 35, keep some spare parts around till you get a better axle. But you will break eventually, and it's always at a bad time, out there on the trail, driving to work. Ditch the 35, don't build it...

 

[CA-RJ]

I ran a D35 with 4:56s and an ARB, 4:1 tcase for years on 33"s with no issues at all. I did many extreme trails for years with no complaints but think you should consider something else if you have the money to spend. A D35 will get the job done but is weaker than either a 44 or a Ford 8.8 which is an easy swap and can include disc brakes. I would opt for the 8.8 (out of Explorer)over a 44 hands down for strength compared to price and easy of swap.

I also ran 33's, 4.88's and a Lockrite on some pretty hard trails and only broke one D35 axle shaft. The problem with running that setup is you have to always remember that you have one (D35) and you can't romp on the gas and hopping is certainly out of the question. I would forgo the Super 35 and save up for an 8.8 so you can have disc brakes as well.

I just did a quick search and found a complete rear end out of a 94 Explorer with 3.73's for $250. You can regear, put new axle seals, new rear pads and rotors, and repaint the housing and have a nice axle ready to go. Then all you need are the brackets.

 

[DrMoab]

The biggest fear I have with D35s or 8.25 axles is the fact that if you break a shaft and don't have a spare you are stuck. I like being able to drive out of a place on a broken shaft with other axles. Or at least get it off the trail.

 

[CA-RJ]

The biggest fear I have with D35s or 8.25 axles is the fact that if you break a shaft and don't have a spare you are stuck. I like being able to drive out of a place on a broken shaft with other axles. Or at least get it off the trail.

Yeah, that is so true. If that D35 shaft breaks at the splines in the carrier, then it really sucks to get the c-clip out to get the broken shaft out. I should have mentioned above, that you should always carry spare shafts if you are wheeling a D35.

 

[Donsfast]

Not sure what you have available where you live but the trick for getting a deal on either a Dana 44 out of an XJ or MJ for easy conversion OR an Explorere 8.8 is the self service type of wrecking yards. You can score an 8.8 for a few hundred bucks thats complete with brakes with just an hour of wrenching. Here we have U-Pull It and I know most metro areas now have similar places.

 

[Overland]

this question comes up over and over on many boards on the net and in all our lives as we buy jeeps. seems the consensus is and has been that putting money into the D-35 is "almost" always a waste. there will always be the guy that wheeld his D-35 on 35's with a detroit in it for years but that is the exception not the rule. if you have the time and or money to wait and build or buy another axle then that is the way to go. a 44, and there are many available from many aplications or an 8.8 there are numerous threads on other forums on what axle to use and everyone has an opinion on the best one. the two mentioned above will be the ones that get the most discussion. both great, both available, lots of talk as to which is better but i think it comes down to what you can find for what money you have to spend.

at my local wrecker all axles (out of anything) are $150.00 regarless of year, model, make. maybe i am lucky but if someone pays $2000.00 for a used 8.8 they are being taken. Waggy 44's are a dime a dozen here as well, they arent in the wreckers but easy to find privately.

good luck and let us know what you decide, always interested.

 

[DrMoab]

A few of the self service yards around here have days where everything is half price. I know guys who have only paid 75-80 for a complete 44 or 8.8.

 

[CoronaKJ]

Wow! great response and info, thanks for the info/advice. I have a 78 waggy at my parents (just sitting) and I believe it has a d44 in the rear. Is this something to look at it? what do I need to look for? I don't recall where the rear diff is located(Right or left) off the top of my head. and does that matter?

 

[Root Moose]

Speaking of fun at the wreckers, apparently there is a wrecker in/near Torontoland that has special Saturdays where you can take whatever you want for $45. If you can carry it out yourself you pay $45.

Gotta go there some day.

 

[Donsfast]

Wow! great response and info, thanks for the info/advice. I have a 78 waggy at my parents (just sitting) and I believe it has a d44 in the rear. Is this something to look at it? what do I need to look for? I don't recall where the rear diff is located(Right or left) off the top of my head. and does that matter?

You are going to need a center diff rear end and the Waggy has a 6 lug pattern that would require different rims. Im not sure of the Waggy rear end length that may be different than the Dana 30 front end you have currently as well. I wouldnt swap just the rear out of a Waggy unless you plan on doing both front and rear.