rear end

[declark2]

I broke my left rear axle and a couple spyder gears in the process... What all can i replace that with that might be a lil stronger for the buck. I have a dana 35 in my 99 tj.....

[Junkpile]

Trying to find a factory D44 from a TJ would be your easiest upgrade. The problem with swapping an axle into a TJ is the bracketry. You can transfer the brackets from your axle to another if you are good with a cutting torch or plasma cutter and a welder. You can send it off to have it done, but shipping gets expensive and the cost isn't very reasonable at most places. Local welding shops would have more than likely never done anything like that, so it would probably be expensive and you might end up with a job that reflects their inexperience. I've never owned a TJ, so there might be options that I'm not aware of though.

There are lots of TJ guys here, I'm sure somebody can help.

The super 35 kit is always an option. It works and provides you with a remarkably strong axle(considering), but it's expensive and at the end of the day you STILL have a D35.

[Bounty__Hunter]

What were you doing when it broke?

Go with the super35 if you think you don't need the extra housing strength of a non-TJ D44. Remember that the TJ D44 has the same thickness axletubes as the D35 so no extra strength to the housing over the D35.

Best bang for the buck is the ford 8.8 from an Explorer, Mountaineer, or Navajo. '95+ has disc brakes and can be found with a limited slip and choice of gear ratios as low as 4.10. You'll have to buy or cut a set of brackets and have them welded on.

[redrooster]

If you put the D35 back together you may as well put a locker in there since it will replace your toasted spider gears.

[mingez]

What were you doing when it broke?

Go with the super35 if you think you don't need the extra housing strength of a non-TJ D44. Remember that the TJ D44 has the same thickness axletubes as the D35 so no extra strength to the housing over the D35.

Is that true Bounty??!

Axletubes ar the same thickness, then why does everyone do this upgrade?? Is it a TJ thing?

I know the D44=more splines... right??

[laneiac]

If you do go with your D35 and install the Super 35 kit that bounty mentioned, throw a truss on it at the same time. It will strengthen the housing considerable, eliminating alot of the bending that is associated with broken axles and loaded diffs.

[Snitty]

in my opinion... leave the 35 out of the question... i'd say go with a real 44 or an 8.8...

bounty... how does the SD35 shaft compare to a 44 shaft

[Joopin]

Is that true Bounty??!

Axletubes ar the same thickness, then why does everyone do this upgrade?? Is it a TJ thing?

I know the D44=more splines... right??

Just the TJs are like this, some XJs have the REAL D44s with the thicker axle tubes, I got mine out of an 89.

[Bounty__Hunter]

The TJ D44 will have larger axleshafts than the D35, and won't have the narrow neck the D35 shafts have where they are prone to snap.

The old XJ and MJ D44's are a lot stronger than TJ D44's, having thicker axletubes for more strength.

Stock D35 axle shafts are 1.18" and 27 spline. Super 35 shafts are 1.31" and 30 spline, an increase in strength of 35% and the same size shaft as most D44's.

Many will argue that the super35 is merely polishing a turd, putting money into an axle and still having a turd axle. If you don't push the jeep hard and the stronger shafts will work for you, I say go for it. If you push the skinny pedal and don't want to fix and put money into something twice, install a real D44 or the Ford 8.8 rear.

[phatyaspen]

as a tj owner that has broken more rearends then michael jackson i can easily say that the super 35 kit is a great upgrade, but if you are gonna run anything larger then a 33" tire then you need to upgrade diffs. I am going to a 35" tire and im getting a dana 60, its overkill btu thats good, and i will never have to worry about my rear snapping again

[redrooster]

What's up with the quick reply screen being gone and my quote function not working.
I had something good to say but now I forgot.

[redrooster]

I quoted myself. What's up with this thing??

[Snitty]

oh i loved the quick reply... that was a GREAT option...

on topic.... is the TJ 44 any better than the Super35?

[mingez]

as a tj owner that has broken more rearends then michael jackson

Awww mannn....

Yeah, what did happen to the quick reply screen?

[hi_c]

phatyaspen... that was hilarious.

Of course the Super 35 kit can be debated. I think you need to consider what you're going to be doing with your jeep. Do you plan on rock crawling or just sticking to mud and dirt trails? If you're staying out of the rocks and staying with 33" or smaller tires, then I would bet that the Super 35 is a great kit. But if you plan on dragging your rearend over some rocks.... upgrade the whole axle. You can an entire D44 out of a junkyard for less than that Super 35 kit... and probably have enough left over to pay someone to re-weld the spring perches for you.

C

[Bounty__Hunter]

on topic.... is the TJ 44 any better than the Super35?

Yes, in R&P size and shaft size only. The 44 does not use c-clips and is not necked down as the 35 is, where it's notoriously week.

You'll still have a relatively weak housing that can be trussed to help compensate.