Dana 35 question

[Sp88mj]

I have 3.07 in my 2wd manche and a hp dana30 with 3.73 i buy for my 4x4 conversion. A friend of mine have a 94xj with 3.73 d35 and wondering if the 94 internal are same than my 88 so i can swap all the gears? Or its easier  to swap the complete xj axle ( not planning to go SOA) 

[Limeyjeeper]

One might be c clip vs non C clip. I can't remember exactly when the changover happened. I think it was in 1994. The non C-clip is marginally stronger. I don't know if the housing changed to accommodate the C clip design if it didn't you should be ok to swap internals. Somebody here will be able to confirm one way or the other.

[derf]

While parts will swap, you don't want to just bolt in axle gears.

 

Variances in the machining processes between the two means you can be off by enough that the gears won't mesh properly and you can have rapid failure.  Of course, they could happen to fit perfectly too.  No way to tell ahead of time.

 

You would at the very least want to go through the install procedure for the gears to make sure they were lined up right.

 

But it's still just a Dana 35 and not really an axle that you want to invest much in.  It's probably less expensive to just take the other Dana 35 and swap out spring perches and shock mounts and run with it.

 

If it were me, I'd look for a Dana 44 or Chrysler 8.25 from an XJ or KJ, swap gears if you need to, then weld on the right spring perches, and run that.

[ghetdjc320]

The changeover to c clips happened in 1990. 1989 and earlier were non c clip. A Dana 35 can be a great axle if you understand its weaknesses and address them. Tire size is a big factor here. What size do you plan on running?

[Sp88mj]

I will run 31’s and it will not be a offroad rig! 
i have a chrysler 8.25 on an xj that a buy to be the donator for my 4x4 swap but they welded the diff so ill have to change all the internals anyway and those pieces are hard to find where i am!

[Pete M]

I would swap the whole axle.  it just needs perches burned on in the right spot. (don't forget that XJ and MJ perches are different widths apart )

[ghetdjc320]

I believe that YJ axles have the same perch placement and distance as the MJ. I’d double check, but could be an option if you find an axle with the ratio you need. If you do swap gears into your axle, get them setup properly. Dana 35 axles need some preload and more often than not I see them set far too loose which causes catastrophic failure. 
 

Keep in mind that a Dana 35 on 31’s can be great for under axle clearances. I ran metric 33’s on mine for many years with 4.56 gears. 

[Sp88mj]

Thanks y’all i will swap the whole axle 

[derf]

5 hours ago, Sp88mj said:

Thanks y’all i will swap the whole axle 

Probably the most cost effective option given how you'll use the truck.

[Gojira94]

9 hours ago, ghetdjc320 said:

Dana 35 axles need some preload and more often than not I see them set far too loose which causes catastrophic failure.

 

Please say more about this - I just set one up with new carrier bearings and outer axle shaft bearings (89 non-c-clip). Made me paranoid I might miss something...