Dana 35 beefing up

[lowranger]

This is the link you sent. I will check with other places. Thank you for your help on this. I was looking for this thread a couple weeks ago to see which one you suggested so I could get them ordered. Glad you posted on here so it came up again.
https://www.summitracing.com/parts/aly-12200/overview/

 

[Eddie Greenlee]

If you install good (!) quality chromoly alloy aftermarket 27 spline axle shafts, they'll be roughly the strength of the OE Dana 44 carbon steel 30 spline shafts

Jerry if I install these axles in my D 35 with the open carrier and 410 gears can i then run 35" tires with confidence on the trails here in MS?

 

[Jerry Bransford]

Jerry if I install these axles in my D 35 with the open carrier and 410 gears can i then run 35" tires with confidence on the trails here in MS?

4.10 isn't enough gear for 35's, what transmission do you have? I'd run 35's with 30 spline 1541H shafts without hesitation.

 

[Eddie Greenlee]

4.10 isn't enough gear for 35's, what transmission do you have? I'd run 35's with 30 spline 1541H shafts without hesitation.

5 speed manual

 

[Jerry Bransford]

5 speed manual

4.88 is appropriate for 35's, 5-speed, and the 4.0 engine. That combination worked well for me on the highway and off-road in my previous TJ.

 

[dla]

Yukon has 4340 27 spline shafts for the Dana 35.

I’m running them with a Detroit Truetrac.

https://www.yukongear.com/productdetails.aspx?ProdID=4485

 

[Jerry Bransford]

Yukon has 4340 27 spline shafts for the Dana 35.

I’m running them with a Detroit Truetrac.

https://www.yukongear.com/productdetails.aspx?ProdID=4485

As has been discovered, 4340 shafts are not a good choice for a Dana 35. The problem is the Dana 35's outer bearings don't have an inner race which causes wear through shafts like 4340 that don't have outer surface hardening like the 1541H shafts do.

This is what happens with 4340 shafts in a Dana 35 and is why we need to run 1541H shafts in a Dana 35. They withstand that bearing wear.

 

[dla]

Here you go Jerry...

https://www.yukongear.com/productdetails.aspx?ProdID=4486

 

[lowranger]

Yukon has 4340 27 spline shafts for the Dana 35.

I’m running them with a Detroit Truetrac.

https://www.yukongear.com/productdetails.aspx?ProdID=4485

Thanks dla!!

 

[Eddie Greenlee]

4.10 isn't enough gear for 35's, what transmission do you have? I'd run 35's with 30 spline 1541H shafts without hesitation.

If i run the 4340 27 spline axles in the stock open carrier, will the weak link be the OEM spider gears and carrier ?

 

[lowranger]

Yukon has 4340 27 spline shafts for the Dana 35.

I’m running them with a Detroit Truetrac.

https://www.yukongear.com/productdetails.aspx?ProdID=4485

My 4:56 gears are Yukon

 

[Jerry Bransford]

If i run the 4340 27 spline axles in the stock open carrier, will the weak link be the OEM spider gears and carrier ?

Don't worry about the spider gears, carrier, etc.,don't give them a second thought... they'll be fine. At least for 99.99%

 

[Rob5589]

If i run the 4340 27 spline axles in the stock open carrier, will the weak link be the OEM spider gears and carrier ?

The 35 spiders are pretty weak. I remember many broken ones, including my own which were already busted when I bought it running on 31's.

 

[Fouledplugs]

The 35 spiders are pretty weak. I remember many broken ones, including my own which were already busted when I bought it running on 31's.

I busted some teeth off factory spider gears running the Dana 35 open with 33’s.

 

[Scout1195]

Some dana 35’s work better then the others to be honest i abuse the hell out of my dana 35 but i do however have chromoly axle shafts and iv not had any issues with it the only issue ive run in too was bending and axle shaft but those were my stock shafts i ran 33 inch tires on my tj and 35 inch and have never had any issues I actually know a guy that runs 37s on his tj with a dana 35 c clip hes had that thing for years and has never had any issues

 

[SkylinesSuck]

Wow, my head hurts. Punctuation man. And this thread is almost 4 years old.