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What parts do I need for a Super 35 conversion?

ScottB

ScottB

TJ Enthusiast
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Aug 6, 2017
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158
Location
Milton, FL, United States
The time has come to update my Dana 35 to a Super 35. I have looked, googled and read a million different sites and forums, but I cannot find a complete list of the parts that I will need to update to the Super 35.

My situation is as follows:
I will NOT be doing this work myself. A professional shop will be doing the work.
I know that when I re-gear the 35 from the stock 3.73 gears, that I will be required to re-gear the front also.
I will be placing an Eaton E-locker in the rear and a Powertrax in the front.
I am currently running 33" and have no intentions of running 35's.

My question is, what is a complete list of parts that I need for a Super 35 conversion?
 
I'm going to add this to the FAQ section once someone gives us a complete answer / parts list. This is a question I see come up often, and it would be nice to have a thread to direct them to with a complete parts list / guide.
 
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Caution on the Eaton E-Locker for the time being, they are having a quality issue in that required welds are not holding. The Super 35 kits only need a Master Install Kit which if you get it from Revolution Gear includes everything needed... pinion & carrier bearings, shims, red Locktite, etc.

But my best recommendation is to have the installing shop source all the parts they will be installing. In other words, don't buy them on your own with the intention of giving them all the parts. The reason for that is if ANYTHING goes wrong during or after the installation, they will very likely just blame the parts you provided... when in reality it's usually the installer that screwed something up. Having them provide all the parts eliminates that possibility and gives you a warranty of both parts and labor.

You may think because the gears & Super 35 kit will come with a warranty will be all you need. The problem is proving to the dealer you bought the parts from that the gears/parts were the problem and not the installer screwing the installation up. Again, it's usually the installer who causes problems but the installing shop and parts dealer will be pointing fingers at each other with you stuck in the middle.
 
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So OP, I'm curious about your decision to want to go to super 35 instead of the popular 8.8 swap. I did the latter and haven't regretted it for a second BUT I also have never heard the arguments of keeping the 35 so that's why I'm curious.

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balfred said:
So OP, I'm curious about your decision to want to go to super 35 instead of the popular 8.8 swap. I did the latter and haven't regretted it for a second BUT I also have never heard the arguments of keeping the 35 so that's why I'm curious.

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Click to expand...
A Super 35 is a lot less work than an 8.8 for the ability to run 35" tires with a locker. One meaningful benefit is that the Dana 35 housing is bit smaller than a Dana 44, while the 8.8 is quite large for what you get -resulting in a loss of ground clearance. The final out the door costs to run an 8.8 are not as inexpensive as many portray them to be. While the Dana 35 is already a perfect fit.

Personally, I would prefer a S35 over an 8.8 any day. Especially if a regear was involved, which it ought to be if the job is to be done well.

2003 Rubicon
 
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balfred said:
So OP, I'm curious about your decision to want to go to super 35 instead of the popular 8.8 swap. I did the latter and haven't regretted it for a second BUT I also have never heard the arguments of keeping the 35 so that's why I'm curious.
Click to expand...

This has been a discussion in my head for many months. I have beat myself up about which way to go until I was so crazy and confused over what to do, that I was just tired of it. I was dead set on the Ford 8.8, but I have had several private discussions with people on this and one other board, all of which guided me to the Super 35.

I know the words, "Building a 35 is just polishing a turd." But I found several (many) folks that went the super 35 route and just beat their Jeep to death with no problems. I'm sure the same can be said for the Ford 8.8.

I mean, any rear end can be broken and most of the time it comes from too much skinny pedal and just not smart driving.

I just made a decision and I went with it. It might be the wrong decision, but I don't think so. If I break this Super 35 through normal use, then it was a lesson learned. And the results of my "poor decision" will be posted here.

Anyway, I got in touch with Allen at AOR and bought the Super 35 kit.

As it stands now, my 05 TJ with a 3" Tera Flex, 8 control arm lift, 33" tires, will be re-geared from the stock 3.73 to 4.88 with Revolution gears, Revolution 30 spline rear axle shafts, a superior truss in the rear and ARB lockers in both the front and rear.

I should be fine with my "polished turd."
 
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ScottB said:
This has been a discussion in my head for many months. I have beat myself up about which way to go until I was so crazy and confused over what to do, that I was just tired of it. I was dead set on the Ford 8.8, but I have had several private discussions with people on this and one other board, all of which guided me to the Super 35.

I know the words, "Building a 35 is just polishing a turd." But I found several (many) folks that went the super 35 route and just beat their Jeep to death with no problems. I'm sure the same can be said for the Ford 8.8.

I mean, any rear end can be broken and most of the time it comes from too much skinny pedal and just not smart driving.

I just made a decision and I went with it. It might be the wrong decision, but I don't think so. If I break this Super 35 through normal use, then it was a lesson learned. And the results of my "poor decision" will be posted here.

Anyway, I got in touch with Allen at AOR and bought the Super 35 kit.

As it stands now, my 05 TJ with a 3" Tera Flex, 8 control arm lift, 33" tires, will be re-geared from the stock 3.73 to 4.88 with Revolution gears, Revolution 30 spline rear axle shafts, a superior truss in the rear and ARB lockers in both the front and rear.

I should be fine with my "polished turd."
Click to expand...
Sounds like its a game of pros and cons and after reading up I don't blame you for sticking with the 35 and just beefing it up. The 8.8 is a big swap and can be costly, I just lucked out on mine so I get where you are coming from. Sounds like a cool project and I'm sure you will love the drivability with the new gears and the confidence in the stronger setup.

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You know, I'm sitting here thinking about this whole Super 35 and Ford 8.8 issue, and I have come to the conclusion that I probably made a bad decision. Both the Super 35 and Ford 8.8 is bad decision.

Here comes the punch line.....................................


I could have saved myself a whole lot of money and lot of time searching and reading, when all I had to do was a couple of small things that would not have cost me anything.

I could have put a couple of Monster Energy and Yeti stickers on the rear window and the diff covers. Those two alone would have taken me anywhere!

Sorry guys, I feeling a little punchy tonight.

Had a total knee replacement 3 weeks ago and I believe the prescribed Oxy might be kicking in.

Friends shouldn't let friends take Oxy and order Jeep parts.
 
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@ScottB I'm sorry if it seemed like I was being negative or something, that wasn't it at all, I had just never heard the pros of keeping the 35. Thanks for the info and it sounds like a solid plan so don't call it a potentially poor decision or a turd, I'm sure it will be awesome

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balfred said:
@ScottB I'm sorry if it seemed like I was being negative or something, that wasn't it at all, I had just never heard the pros of keeping the 35. Thanks for the info and it sounds like a solid plan so don't call it a potentially poor decision or a turd, I'm sure it will be awesome
Click to expand...

No worries, I didn't take your post as anything negative. Opinions and differences are a fact of life. I might have made the wrong decision, but I have made wrong ones in the past.................................. just ask my wife.:tiburon:
 
Other than spending money on something, what was the wrong decision? What would have been a better one?

2003 Rubicon
 
There are those that are well trusted that have no issue with the S35, running 35's, in some of the gnarliest terrain around. The 8.8 became popular due to availability, not because it is some super strong wonder diff.
 
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Rob5589 said:
There are those that are well trusted that have no issue with the S35, running 35's, in some of the gnarliest terrain around. The 8.8 became popular due to availability, not because it is some super strong wonder diff.
Click to expand...
I don't think anyone was saying it was a super strong diff in comparison to the super 35, I was just asking a question to learn about it because I knew nothing about the super 35. The guy who did my 8.8 swap seemed to think it was the way to go so I just trusted that was the best option since I'm just learning that you can upgrade the 35 to make it good for 35s

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Support for converting 8.8 axles for use in TJs is waning, it's just not worth the effort in a growing percentage of builder's opinions.
 

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