Blown D35

[EMS 34 20]

My 35 blew up last Thu started the surgery today. Pulled the cover found 2 teeth in the bottom and 4 missing off the pinion. Got the Chry 8.25 torched all the mts off and set the new spring pads,weld them and the shock mts on tomorow then I'm good to go untill I get a 8.8 and a sye.

[DrLewall]

am counting the days..and my fingers are crossed with massive hopes of luck, that my D35 will hold until I can get the chance to install my 8.8..would REALLY suck if it decide to blow at hwy speed!

[OhioYJ]

Join the club.....

http://www.cdmfabrication.com/bbpics/broken35.jpg

So and that was on 31s? I'm getting tired of everytime the Dana35 being a ticking time bomb comes up, you get the people coming out of the wood work that say the Dana35 is fine, because they've wheeled it for however long and never had a problem. I've seen Dana35s self destruct on the street on the factory 27" tires....

The 8.25 especially the later 29 spline versions, lack afternarket support, and while essentially Chrysler's Dana35, I still consider it to be a fair amount stronger than the Dana35. I'd still plan on an 8.8 swap, but the 8.25 will hold up better than the Dana35.

[Bada-Bing.]

After my first D35 blew up, I have never trusted them and cringe when people but big tires and lockers in that axle.

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v232/127/45/31709574/n31709574_32840280_7612.jpg

Now on my TJ I trust my 8.8 for 33's
http://photos-e.ak.fbcdn.net/photos-ak-sf2p/v252/187/42/9316795/n9316795_48049884_6484.jpg

[EMS 34 20]

Man Bada-Bing that looks like that HURT!! I plan on doing the 8.8 but the $$$ are not available right now so I did the 8.25. The rear is in took it to my Amish welder to have the shock mts put on (it was fun driveing with no shocks) all total cost$210.00 $100. rear, $30.U-bolts,$25 spring pads,$20 shock mts,$35 welding. So it's all fixed hope to do the 8.8 next summer.

[zc0717]

After my first D35 blew up, I have never trusted them and cringe when people but big tires and lockers in that axle.

http://photos-a.ak.fbcdn.net/photos-ak-sf2p/v232/127/45/31709574/n31709574_32840280_7612.jpg




im guessing this happened at high way speeds?????

[Rubiconrich]

Don't forget about the Dana 44 rear end.

[Knuckelhead]

Go (shaved) 9". 3/4" more clearance than a d35...:)
http://i42.photobucket.com/albums/e333/knuckelhead/floatingtj.jpg
http://i42.photobucket.com/albums/e333/knuckelhead/rearflex12.jpg
http://i42.photobucket.com/albums/e333/knuckelhead/rearflex13.jpg

[Bada-Bing.]

Yeah, that crash hurt. Passanger broke his pelvis and ribs. Rear Axle snapped, locker pulled me 90 degrees left into oncoming traffic and was t-boned by the Landrover in the picture. Police estimated we were each doing 45-55 so thats a 90-110mph impact. There was a hardtop on there. Weirdest feeling, waking up looking into the tree tops and wondering where the top went.

[Rubiconrich]

9" 's are good but so is The Dana 44. I'd go with one of these before a 8.8.

[4LWranglerTJ]

Go (shaved) 9". 3/4" more clearance than a d35...:)
http://i42.photobucket.com/albums/e333/knuckelhead/floatingtj.jpg
http://i42.photobucket.com/albums/e333/knuckelhead/rearflex12.jpg
http://i42.photobucket.com/albums/e333/knuckelhead/rearflex13.jpg

I have fallen in love with your 9" more and more after each time you post about it. I am just curious because there is not much info on swapping these into TJs, what did you swap it out of?, I assume you had to shorten it and the shafts?? and how much was the total swap? It is probably not ideal for me because I cant weld but can you plz tho that info at me? Sry for hijacking but i thought others could use this info too.

[Bada-Bing.]

Currie 9" rear end - which I believe KH bought his from

Housing - 400
TJ brackets - 450 YJ brackets are obviously cheaper
Bottom Skid - 95
Shaved bottom - 160
Powder coat - 150

Thats already 1200 not including 3rd member/gears/lockers/ etc which is another grand or so
Also need axle shafts, brakes, etc

Here is one on Craigslist already assembled with 4.10's and a detroit for $1500
http://phoenix.craigslist.org/nph/pts/1270211522.html


No doubt as far as quality out of the 44 8.8 and 9 the 9 is the best with amazing aftermarket support and for a vehicle as light as a jeep the only reason to not go this route is cost. You will spend the most on a 9", then the 44 and the 8.8 will be the cheapest. As far as strength the 9" is the strongest, then the 8.8 then the 44.

[MJMPC]

9" 's are good but so is The Dana 44. I'd go with one of these before a 8.8.

Why ??

[OhioYJ]

9" 's are good but so is The Dana 44. I'd go with one of these before a 8.8.

Let me guess the Dana44 is good because that's what you have under your Jeep? The Ford 8.8 is much stronger than a Dana44, and easier to come by. Typically for most people, even paying someone to weld brackets on the 8.8 turns out to be cheaper or the same price as the Dana44, but you still get a stronger axle. The 9" can be built to be stronger (or as strong) than 1-ton axles, and be built cheaply, so yeah you are right there they are good, even in stock form they are a very strong axle.

[pdapkus08]

Ya I know the pain of the D35 snap... Easing of the clutch to get outa a parking spot at my school and crack. It was cold and snowy but if the axel snaped from that I don't wanna know how close the axel came to snaping when I'm on the highway or way out in the woods.

But on another note I have snapped an 8.8 as well. I was cruzing down the road in my first car, 91 mustang gt... Well ok I wasn't exactly cruising, I was going about 120mph and was cornering over a slight hill easing left. The weight of the car came off over the hill but when it came back on my left axel broke at the drum and my locker tossed me into an uncontrolabale drift.

I rolled it 8 times after launching over a rock wall into a tree, then rebounded off the tree over the powerlines like a goal kick.
http://i110.photobucket.com/albums/n112/nyx_thmeghan/l_e858e9a73a8e93563b1627b673977b31.jpg
http://i110.photobucket.com/albums/n112/nyx_thmeghan/l_602dc49ad7b5f883d0fc798b619cc9c3.jpg
http://i110.photobucket.com/albums/n112/nyx_thmeghan/l_1fe0d48ddefff6486a5e5dd27a0b7ab5.jpg

[Skadsy]

ouch. that hurts. good thing you switched to a nice and slow moving jeep. haha!

[Bada-Bing.]

Ya I know the pain of the D35 snap... Easing of the clutch to get outa a parking spot at my school and crack. It was cold and snowy but if the axel snaped from that I don't wanna know how close the axel came to snaping when I'm on the highway or way out in the woods.

But on another note I have snapped an 8.8 as well. I was cruzing down the road in my first car, 91 mustang gt... Well ok I wasn't exactly cruising, I was going about 120mph and was cornering over a slight hill easing left. The weight of the car came off over the hill but when it came back on my left axel broke at the drum and my locker tossed me into an uncontrolabale drift.

I rolled it 8 times after launching over a rock wall into a tree, then rebounded off the tree over the powerlines like a goal kick.
http://i110.photobucket.com/albums/n112/nyx_thmeghan/l_e858e9a73a8e93563b1627b673977b31.jpg
http://i110.photobucket.com/albums/n112/nyx_thmeghan/l_602dc49ad7b5f883d0fc798b619cc9c3.jpg
http://i110.photobucket.com/albums/n112/nyx_thmeghan/l_1fe0d48ddefff6486a5e5dd27a0b7ab5.jpg


As nasty as that is and you are right, there is an 8.8 in that but my guess it was the aluminum version of the 8.8 with 27 spline count shafts (i think). The ones out of a 96+ explorer are much heavier duty and are a cast housing w/ steel tubes and 31 spline

[OhioYJ]

<--- Guess who is a Mustang guy.... :D Actually probably still know more about the Mustangs than I do Jeeps. The Mustang 8.8 is a steel housing, but it is thinner wall housing, with 28 spline shafts. The 28 spline shafts do break from time to time, thats why many people upgrade to the 31 spline shafts (Explorer 8.8s have 31 spline shafts).

Never broke the 8.8 in my Mustang though even on the 28 spline shafts, and that was going to the track every week.

[Knuckelhead]

It is probably not ideal for me because I cant weld but can you plz tho that info at me? Sry for hijacking but i thought others could use this info too.

Currie 9" rear end - which I believe KH bought his from

Housing - 400
TJ brackets - 450 YJ brackets are obviously cheaper
Bottom Skid - 95
Shaved bottom - 160
Powder coat - 150

Thats already 1200 not including 3rd member/gears/lockers/ etc which is another grand or so
Also need axle shafts, brakes, etc

Yes. After bending 3 axle shafts and cracking 1 spindle on the Warn d35 full floater, I had currie build my 9" and it wasn't cheap!
http://i42.photobucket.com/albums/e333/knuckelhead/shaft.jpg

Custom width
HD housing
Explorer drum/disc brakes
Dual drilled stud holes (5x4.5, 5x5.5)
35 spline shafts
ARB locker
Shaved housing
Currie, triangulated "J" arm 4 link
Currie, HP 3rd member
Currie, reinforced upper frame control arm mounts
Currie, upper shock relocation mounts

If I remember, it was around $3,700 (4 years ago).
I got tired of breaking things after installing 35" tires.
I have had zero problems with this axle after installing it.
http://i42.photobucket.com/albums/e333/knuckelhead/shaved9inch.jpg
http://i42.photobucket.com/albums/e333/knuckelhead/rear9inch.jpg
http://i42.photobucket.com/albums/e333/knuckelhead/linkend.jpg
Expensive, yes. Peace of mind while wheeling, you bet! Until you have a triangulated suspension set-up, you won't understand...:)
Oh, I did the paint...:D

[pdapkus08]

No is was a steel axel actually. I guess I should have mentioned that there was a small crack that had formed and rusted a little bit right under the drum where it snapped off. Probably because someone had curbed it at one point.

I think the aluminum axel wasnt introduced untill the forth gen mustangs. (the ones with the weird wavy sides)

I really miss my mustang. After my jeep is payed off and built I plan on getting another fox body just because they really are the ultimate tuner car. That thing was more fun to work on than the jeep and it had more trunk space :thumbsup:

[Jesse-James]

9" 's are good but so is The Dana 44. I'd go with one of these before a 8.8.

Please explain, I really want to hear your logic behind this one.