Dana 35 Break

[Ryan Yohanis]

I'd like to hear who has broken they're Dana 35, where it broke, what the drivetrain was, how the driving was, and tires in use.

 

So, shafts, ring and/or pinion, spiders? 4.0/2.1/2.5/5.7? Manual or auto? Turning a corner or sudden traction? Bald all seasons or bias plys?

 

Main reason for the post is I'm curious how worried I should be with a 2.5 and a 904 on 31 or 33" MTs.

[89 MJ]

How you drive it is going to be a large factor. You can also get upgraded parts for D35s too.

[Pete M]

blew the ring/pinion gear teeth running 30" tires on a 2wd 4.0/stick daily driver.  ended up bending the axle.   though that might have been due to the next half mile of driving since there's no way I was walking the rest of the way to work if the truck still technically moved.  lol 

[derf]

Watched a guy in a stock TJ trying to climb a small ledge.  His spotter just shouted "Give it more gas!"

 

A rev of the engine, a loud pop, and the shaft started to walk out...

 

Moral of the story?  More gas is never the answer with a Dana 35.

[camjeep3]

4.0 5 SPD. 307 gears. Just put new 33x13.5 super swampers on. Was showing off (in highschool) attempted to neutral drop. Dumped the clutch. Truck never moved. Loud bang followed by a stripping noise. Peeled all the teeth off the ring gear. 

[Htchevyii]

Somehow, I never broke the Dana 35, just the Peugeot trans. I did however, buy two different Dana 35's that had broken ring gears, so I suspect that to be a weak point. 

[derf]

11 minutes ago, Htchevyii said:

Somehow, I never broke the Dana 35, just the Peugeot trans. I did however, buy two different Dana 35's that had broken ring gears, so I suspect that to be a weak point. 

To be fair, the Peugeot is weaker than a Dana 35...

[AZJeff]

As a daily driver with incorporates light off-roading, a D35 is just fine.  People break them when they install monster wheels/tires or do stupid stuff like dropping the clutch.

[pizzaman09]

My first Comanche with a Peugeot trans and D35 was very smooth and nice to drive on the street.  It had stock sized tires.  My current MJ with an AX-15, and an LSD equipped D44 is not nearly as smooth or nice to drive on the street.  Similar sized tires.  It kinda doesn't enjoy tight corners or any corner after it gets hot.

 

To be on topic I have not broken a D35.

[camjeep3]

39 minutes ago, AZJeff said:

As a daily driver with incorporates light off-roading, a D35 is just fine.  People break them when they install monster wheels/tires or do stupid stuff like dropping the clutch.

I resemble that statement 

[Htchevyii]

9 hours ago, derf said:

To be fair, the Peugeot is weaker than a Dana 35...

Mine was! The 35 lived through a surprising amount of abuse, I think the small tires saved it. I was 20 when I got it and was definitely not easy on it. That was a long time ago!

[ghetdjc320]

On 10/1/2025 at 1:01 AM, Ryan Yohanis said:

 

I'd like to hear who has broken they're Dana 35, where it broke, what the drivetrain was, how the driving was, and tires in use.

 

So, shafts, ring and/or pinion, spiders? 4.0/2.1/2.5/5.7? Manual or auto? Turning a corner or sudden traction? Bald all seasons or bias plys?

 

Main reason for the post is I'm curious how worried I should be with a 2.5 and a 904 on 31 or 33" MTs.

So you’re looking for horror stories? Why not ask about those who have had no issues with their axles as well? If all you’re looking for is problem stories, you’ll be worried