If I were to upgrade my axle shafts retaining the 27 spline setup, would that be sufficient for light wheeling?

TGringleJeep

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I know the topic of whether to upgrade the Dana 35 or replace it has been beaten to death. I apologize if there is a thread I have missed prior to this post. I have owned my 2005 4.0 tj for over 10 years. It is 3.5in lifted rolling on 33s 3.07 ratio 6 speed manual. I do not plan on installing a locker as I only do light wheeling through mostly mud or sometimes snow. My question; If I were to upgrade my axle shafts retaining the 27 spline set up would that be sufficient for light wheeling? The jeep has been lifted for the prior 5 years and I have decided it’s not worth the money to me to upgrade to Dana 44. Any advise would be greatly appreciated.
 
I would only run a locker in a Dana 35 after installing a Super 35 kit that includes 30 spline 1541H axle shafts. Revolution Gear & Axle makes a good Super 35 kit.
 
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I would only run a locker in a Dana 35 after installing a Super 35 kit that includes 30 spline 1541H axle shafts. Revolution Gear & Axle makes a good Super 35 kit.
Sorry I’m new here. I should have been more clear that I do not intend to install a locker. I’m wondering if a stock Dana 35 with upgraded 27 spline shafts is sufficient for light wheeling with 33s. Also, Jerry thank you for all you have contributed to the jeep community. I have been reading your posts as a non member for a while now.
 
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Sorry I’m new here. I should have been more clear that I do not intend to install a locker. I’m wondering if a stock Dana 35 with upgraded 27 spline shafts is sufficient for light wheeling with 33s.
Whoops sorry, I thought you were perhaps getting interested in a locker. Without a locker a stock Dana 35 is usually up to wheeling with 33's without a problem. I wouldn't expect stock Dana 35 shafts to break with 33's unless the driver was a complete idiot and was hammering his Jeep through the trail.
 
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Whoops sorry, I thought you were perhaps getting interested in a locker. Without a locker a stock Dana 35 is usually up to wheeling with 33's without a problem. I wouldn't expect stock Dana 35 shafts to break with 33's unless the driver was a complete idiot and was hammering his Jeep through the trail.
Thank you very much! I’m not doing any hammering through the trails or rock climbing. I’m a slow and steady type of driver off road. I just don’t want to get stuck on the trail with a broken axle. I’ll keep the stock set up.
 
It's always a possibility (breaking something). My friend had a Dana 35 and 35" tires for many years and didn't break it. I did it myself for a few years. I always let off the skinny pedal when the rear end started hopping. It was ALWAYS in the back of my mind though. :(
 
As others have posted; LOCKERS and the Dana 35 do not mix well.
IF you upgrade your gearing; since you live in the Seattle area.... consider installing a Detroit TruTrac gear drive Limited Slip traction device.
The TT has good road manners while performing well in snow and dirt.
 
Whoops sorry, I thought you were perhaps getting interested in a locker. Without a locker a stock Dana 35 is usually up to wheeling with 33's without a problem. I wouldn't expect stock Dana 35 shafts to break with 33's unless the driver was a complete idiot and was hammering his Jeep through the trail.
Jerry, I have 35" does that change your assessment on shaft breaking?
 
Jerry, I have 35" does that change your assessment on shaft breaking?
Yes, 35" tires will break the factory Dana 35 axle shafts.

This is what happened to a friend's Dana 35 axle shaft while wheeling with 35" tires. I was right behind her and heard it break. It took us the rest of the day to get and install a replacement axle shaft.

Marianne640x480.jpg
 
Yes, 35" tires will break the factory Dana 35 axle shafts.

This is what happened to a friend's Dana 35 axle shaft while wheeling with 35" tires. I was right behind her and heard it break. It took us the rest of the day to get and install a replacement axle shaft.
That is what I was afraid of, so it seems like upgrading the shafts is the bare minimum with 35" tires
 
Yes, you can easily do that with the Super 35 kit which has a solid reputation.
My local shop who has a solid reputation told me today we could always truss and gusset the Dana 35. I am not sure what that means, but would that solve the issue of the 35 breaking the shaft?
 
My local shop who has a solid reputation told me today we could always truss and gusset the Dana 35. I am not sure what that means, but would that solve the issue of the 35 breaking the shaft?
Don't waste your $$$, trussing/gusseting the Dana 35 is of no use and would not solve the issue of the axle shaft not being strong enough. Installing a Super 35 is all you need to do. Not to mention that the Dana 35's axle tubes the shafts pass through are the exact same axle tubes used on the Dana 44. They are cut from the exact same tube stock.
 
Anything can break...but my goodness take your rig out as is and have fun. If sonething happens no big deal. Cross that bridge then.

It sucks you have 3.07's but seriously to just go "light wheeling"..
Hell go heavy wheeling.

You don't have 500 hp and 44" boggers with insane leverage.

33" tires and open diff...
You'll be fine...

Go wheeling brotha!!!
Enjoy the Jeep!!
 
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