2002 TJ, broken axle

[dylansalrin]

If any of you from the southern Calif area, check our Hard Rock 4x4. John and Frank are great. Www.jeep911.com


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X2. I've been there, you'll definitely find whatever you are looking for. Be prepared to pawn stars the shit out of them though lol. They ask for a higher price thinking you won't counter. I got limiting straps and shackles from $50 down to $20

 

[JimmyMac]

There prices have been more than reasonable. Someone stole my break drums from the back of my truck, with all the break components. The gave me (no cost) all. Needed to get back on the road ($200 retail). They offered to install a 4.56 ring/pinion w/carrier for $75 labor. I can't bargain that. I can't say enough for these guys


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[Forty]

That climb is typical of events that can cause Dana 35 breakages, especially if there was any axle bounce going on. It's simply not a robust axle, its smallish diameter 27 spline axle shaft likely snapped right at where it enters the differential's side gears which is at the base of the splines.

These photos typical Dana 35 breakages... http://www.billhughes.com/dana35c/

Replacing the entire axle with a used TJ Dana 44 would be optimal and the easiest. The issue is those TJ Dana 44 axles have become precious commodities and aren't always priced reasonably. Other possibilities include installing a Super 35 kit from www.revolutiongear.com as sold by www.4lowparts.com or adapting a Ford 8.8 axle which is not easy or cheap either unless you are a fair fabricator and know how to weld and get it installed on your own.

This photo shows the stock Dana 35 axle shaft, 1.18 inches in diameter with 27 splines (left). The Super 35 shaft in comparison on the right is 1.31 inches in diameter and has 30 splines for a strength gain of over 35 percent.

View attachment 10542

Someone was in the army

 

[JimmyMac]

Update. I replaced the rear with a Dana44 w/ Detroit locker and 4.56 ring/pinion. I am having the front Dan 30 carrier and ring/pinion replaced with a 4.56 true track. Still have a week point in front, but should last me a while. No more camacazi hills.


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[Chris]

Good to know you've got the rear all replaced!