Long time lurker with a semi-lengthy post. Wife says I am getting buried in my Jeep because of the amount of time and money I have sunk into this thing. I had one as a young jarhead and got rid of it when the little ones come along, but now that they are grown, I decided to get another. I know the Dana 35 debate has been beat to death but looking for some advice on what to attempt to do next. I bought a 2000 TJ off of a local high school student that was just looking for a down payment for a new to him car. I bought this thing for $1000 with 250K on the odometer some problems that I knew I was getting into. This was going to be a project for me post-retirement from the Marine Corps to build out the way I was wanting over time.
The frame had some major frame rot (vehicle was originally from NJ, and I sure the salt air here is Charleston probably doesn't help matters), replaced the frame with a Throttle Down Customs new frame, couldn't find a shop or welder in my area that was willing to do the frame caps/repair and I don't trust my welding skills enough for that job. After driving this thing for about 30K miles, the 5-speed failed so that was replaced (couldn't find a decent junkyard to rebuild but did find one rebuilt NV3500 at the time) Advanced Adapters had a new manufacture AX15 for cheaper than the rebuilt NV3500, so ordered that and put it in.
I had the motor blow about 5K after the new tranny was installed (it had a knock from the start and was getting the Cylinder 1 misfire code. I pulled the motor and shipped it off to S&J engines (didn't have the time to do myself due to travel for work) and had a low buck 4.7L stroker built and with upgraded head. So, while the motor was out, I figured it was time to start really digging into the drive train (axles, bearings and seals) and steering, so how I didn't ever notice this while driving it was beyond me (never heard popping or the ratcheting sound).
When I pulled apart the rear Dana 35 to check the condition of the components inside, I found out that someone along the line has installed a Spartan locker, everything I have read leads me to believe this is a disaster waiting to happen. For now, the Jeep has a small 2-inch lift, and a 1-inch body lift and is only running 31-inch tires, I plan on putting new wheels and tires when the 31 wear out, still should have about 20K or so left on them. At that point I was planning on stepping up to 33s. So the question becomes, wait for the Dana to grenade and build out a Super 35 or keep looking for a Dana 44, I figure the cost in the end will be about the same after sourcing a used Dana44 and all the parts to rebuild it.
@Jerry Bransford seems to be the powerhouse of knowledge on here and would love to hear his take on this, with anyone's opinion/experience. I searched on the forums but didn't see anyone with a stroker and a Dana 35 probably because it's a recipe for trouble. I don't trust my welding skills enough to build a 8.8 rearend and the axle assemblies at ECGS are a little more than I want to invest at this point. However, even with the cash I have sunk into this I still think I'm about $25k ahead of what I would have spent on a new Jeep.
The frame had some major frame rot (vehicle was originally from NJ, and I sure the salt air here is Charleston probably doesn't help matters), replaced the frame with a Throttle Down Customs new frame, couldn't find a shop or welder in my area that was willing to do the frame caps/repair and I don't trust my welding skills enough for that job. After driving this thing for about 30K miles, the 5-speed failed so that was replaced (couldn't find a decent junkyard to rebuild but did find one rebuilt NV3500 at the time) Advanced Adapters had a new manufacture AX15 for cheaper than the rebuilt NV3500, so ordered that and put it in.
I had the motor blow about 5K after the new tranny was installed (it had a knock from the start and was getting the Cylinder 1 misfire code. I pulled the motor and shipped it off to S&J engines (didn't have the time to do myself due to travel for work) and had a low buck 4.7L stroker built and with upgraded head. So, while the motor was out, I figured it was time to start really digging into the drive train (axles, bearings and seals) and steering, so how I didn't ever notice this while driving it was beyond me (never heard popping or the ratcheting sound).
When I pulled apart the rear Dana 35 to check the condition of the components inside, I found out that someone along the line has installed a Spartan locker, everything I have read leads me to believe this is a disaster waiting to happen. For now, the Jeep has a small 2-inch lift, and a 1-inch body lift and is only running 31-inch tires, I plan on putting new wheels and tires when the 31 wear out, still should have about 20K or so left on them. At that point I was planning on stepping up to 33s. So the question becomes, wait for the Dana to grenade and build out a Super 35 or keep looking for a Dana 44, I figure the cost in the end will be about the same after sourcing a used Dana44 and all the parts to rebuild it.
@Jerry Bransford seems to be the powerhouse of knowledge on here and would love to hear his take on this, with anyone's opinion/experience. I searched on the forums but didn't see anyone with a stroker and a Dana 35 probably because it's a recipe for trouble. I don't trust my welding skills enough to build a 8.8 rearend and the axle assemblies at ECGS are a little more than I want to invest at this point. However, even with the cash I have sunk into this I still think I'm about $25k ahead of what I would have spent on a new Jeep.
