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  • Rebuilding my rear end

    Can anyone give me som advice on rebuilding my Dana 35? It seems pretty straight forward, but I want to do it right.

    Thanks!
    Chris - Sgt g33k
    06 TJ


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  • #2
    Well.. a few questions first,

    What do you do with your Jeep? Daily Driver? Mud? Rocks? etc..
    What size lift if any do you have?
    What size tires do you have.

    The reason I ask is because the Dana 35 has a few very notable weaknesses.
    The Axles are held in with a C clip which means if you break an axle shaft it will fall out.
    The shafts themselves are also quite weak.

    If you are looking to do any serious wheeling id suggest getting a Dana 44, Ford 8.8 or Ford 9 rear and swapping them.
    I personally swapped a TJ Dana 44 Limited Slip into mine and never looked back.


    If you arent down for a type swap your obvious options are a swap for another D35 with the same ratio which should be quite cheap
    The other option is to re-gear. This can be expensive and time consuming and requires tools you probably dont have and skills that go along with them.

    Here is an example of someone replacing the gears: https://www.youtube.com/watch?v=TF7baS3Ebb4
    Last edited by mamefreak; 11-24-2015, 01:21 AM.
    2003 TJ X - Light Metallic Khaki and Black "Blackout Special" on 33x12.5 Wrangler MT/R Kevlar Tires
    M101 CDN2 Trailer on 33x12.5 Wrangler MT/R Kevlar Tires

    More mods than can fit in a signature ;-)

    My Build Thread

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    • #3
      It was my daily until it broke. I would like to make it more my weekend/winter warrior.

      It has a lift from the previous owner. Looks like a spring lift.

      I am running 31 x 10.5 on stock 16"

      Ultimately I would like to swap to a D44 but not sure if the cost.


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      • #4
        Your in the right hands with TJ.... Get ready to take notes!! LET HIM HAVE IT TJ!! LOL
        CDJW.org - Founder
        2016 Rubicon
        Awesome wife...

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        • #5
          Originally posted by Sgt G33K View Post
          It was my daily until it broke. I would like to make it more my weekend/winter warrior.

          It has a lift from the previous owner. Looks like a spring lift.

          I am running 31 x 10.5 on stock 16"

          Ultimately I would like to swap to a D44 but not sure if the cost.


          Sent from my iPhone using Tapatalk
          Well your current setup is well within the limits of the D35.
          If you start spinning 33x12.5 then an upgrade is basically mandatory ( some will disagree but its only a matter of time )

          A TJ D44 is going to run you all of $750-$1000 but is easy direct bolt in ( although you may need your drive shaft shortened )
          I paid $800 for mine but sold my working D35 for $500.

          I just kept posting on Craigslist ( also make sure to make a post here ) and a fellow club member sold me his.

          A 8.8 or 9 inch rear will end up costing you about the same WITH someone installing the correct brackets as well.
          You just need to match your ratio.
          They are much easier to come by from junk yards and places like Jerry Browns in Queensbury.
          Last edited by mamefreak; 11-24-2015, 01:33 AM.
          2003 TJ X - Light Metallic Khaki and Black "Blackout Special" on 33x12.5 Wrangler MT/R Kevlar Tires
          M101 CDN2 Trailer on 33x12.5 Wrangler MT/R Kevlar Tires

          More mods than can fit in a signature ;-)

          My Build Thread

          Comment


          • #6
            Originally posted by janderson View Post
            Your in the right hands with TJ.... Get ready to take notes!! LET HIM HAVE IT TJ!! LOL
            Hahah Thanks Jay
            2003 TJ X - Light Metallic Khaki and Black "Blackout Special" on 33x12.5 Wrangler MT/R Kevlar Tires
            M101 CDN2 Trailer on 33x12.5 Wrangler MT/R Kevlar Tires

            More mods than can fit in a signature ;-)

            My Build Thread

            Comment


            • #7
              I rebuilt my t-case over the summer and put in a SYE so the rear drive shaft is all set.

              A ford 8.8 sounds promising. My ratio says 3.08 on the build sheet.

              The previous owner had it lifted but wasn't done right.

              I bought it a year ago after my 2000 TJ was totaled in an accident (while parked)


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              • #8
                Originally posted by Sgt G33K View Post
                I rebuilt my t-case over the summer and put in a SYE so the rear drive shaft is all set.

                A ford 8.8 sounds promising. My ratio says 3.08 on the build sheet.

                The previous owner had it lifted but wasn't done right.

                I bought it a year ago after my 2000 TJ was totaled in an accident (while parked)


                Sent from my iPhone using Tapatalk
                Hmm.. might have a harder time finding a 3.08 on 8.8. BUT! what you could do is find one with destroyed gears already and have it re-geared at the same time.
                Most of the time i see 3.73, 4.10 and 4.56 as the most common ratios overall.
                2003 TJ X - Light Metallic Khaki and Black "Blackout Special" on 33x12.5 Wrangler MT/R Kevlar Tires
                M101 CDN2 Trailer on 33x12.5 Wrangler MT/R Kevlar Tires

                More mods than can fit in a signature ;-)

                My Build Thread

                Comment


                • #9
                  or buy one with better gearing, 3.73 or 4.10 and regear the other axle.
                  CDJW.org - Founder
                  2016 Rubicon
                  Awesome wife...

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                  • #10
                    Originally posted by janderson View Post
                    or buy one with better gearing, 3.73 or 4.10 and regear the other axle.
                    also a great idea, and dana 30 axles are stupidly cheap!
                    2003 TJ X - Light Metallic Khaki and Black "Blackout Special" on 33x12.5 Wrangler MT/R Kevlar Tires
                    M101 CDN2 Trailer on 33x12.5 Wrangler MT/R Kevlar Tires

                    More mods than can fit in a signature ;-)

                    My Build Thread

                    Comment


                    • #11
                      Sounds like a lot of time under the jeep this winter.


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                      • #12
                        Originally posted by Sgt G33K View Post
                        Sounds like a lot of time under the jeep this winter.


                        Sent from my iPhone using Tapatalk
                        Well, the front axle swap should be reasonably easy at least :-D
                        Id post on Craigs and see if anyone has a D44 first though for the easy swap
                        2003 TJ X - Light Metallic Khaki and Black "Blackout Special" on 33x12.5 Wrangler MT/R Kevlar Tires
                        M101 CDN2 Trailer on 33x12.5 Wrangler MT/R Kevlar Tires

                        More mods than can fit in a signature ;-)

                        My Build Thread

                        Comment

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