4340 Chromoly shafts in a Dana 35...

[dla]

A little over two years ago I requested that my shafts be replaced with Yukon 4340's when I re-geared and added a Truetrac. Shortly after that is when I saw the post by @mrblaine showing the photo of the worn shaft where the bearing rides and his recommendation to never use 4340 shafts in a Dana 35. I think his exact words words were along the lines of "I'd be very afraid...". During my prior research I had not found anything with regards to this problem.

Other than that first warning and now all the others repeating it every time the topic comes up I have not heard of or seen any other failures. There was no mention of failures or problems by my installer, Robert whom If I'm not mistaken works with or does work for Blaine from time to time.

At this point do I need to pull my shafts periodically and check for wear? Swap them out for 1541H shafts asap? Or run them and wait for them to possibly fail?

The Jeep is used around town and a weekend toy that gets pulled behind our motorhome and is used for desert exploration and moderate trails.

 

[Rob5589]

Interesting conundrum. Only way to know is pull em and see how they look.

 

[Mr. Bills]

. . . At this point do I need to pull my shafts periodically and check for wear? Swap them out for 1541H shafts asap? Or run them and wait for them to possibly fail. . . ?

Door Number Three: Replace them if/when they fail.

 

[Jerry Bransford]

The problem is the Dana 35's outer shaft bearings ride directly on the shaft, not on a bearing race like on a Dana 44 axle shaft uses. A 1541H shaft has its surface specially hardened as to stand up to the bearings constantly rolling on the surface. 4340 shafts have a different treatment process that doesn't harden the surface enough for the Dana 35's type of bearings.

 

[dla]

The problem is the Dana 35's outer shaft bearings ride directly on the shaft, not on a bearing race like on a Dana 44 axle shaft uses. A 1541H shaft has its surface specially hardened as to stand up to the bearings constantly rolling on the surface. 4340 shafts have a different treatment process that doesn't harden the surface enough for the Dana 35's type of bearings.

I'm aware of that now. Would not have gone with them if I knew that before.

 

[Benjeepn]

The problem is the Dana 35's outer shaft bearings ride directly on the shaft, not on a bearing race like on a Dana 44 axle shaft uses. A 1541H shaft has its surface specially hardened as to stand up to the bearings constantly rolling on the surface. 4340 shafts have a different treatment process that doesn't harden the surface enough for the Dana 35's type of bearings.

So it uses a bearing like this?

 

[Jerry Bransford]

Yes, exactly.

This is what the SET10 bearing looks like that gets used on the Dana 44 axle shafts.

 

[tjryder]

Bumping this Topic up. As I found myselve in this pitfall.
I had a broken carrier - let' do teh re-gear, while in - let's do the Eaton e lockers and - since shafts have warn bearing surface - let's go cromoly.
And since I live in Europe - all the parts cost double due to shipping ans taxes.

Is there a bearing kit like the mentioned Dana 44 style bearings for the moly Dana 35 shafts?

Many thanks in advance

 

[tjryder]

Or - if not - can someone reliably confirm outer bearing size, shaft size and width so I can search for something that would fit?

 

[Rickyd]

Or - if not - can someone reliably confirm outer bearing size, shaft size and width so I can search for something that would fit?

You want a super35 kit with 1541h shafts. Bearing size isn't going to help.there is no bearing retainer on a Dana 35 to allow you to do what you want

 

[Strizzo]

would a C-clip eliminator not solve the problem? I believe it replaces the outer bearing with a captured bearing/race and axle retainer. where it could be an issue is if you have to turn down the chromoly shaft to fit the new bearing.

 

[lBasket]

would a C-clip eliminator not solve the problem? I believe it replaces the outer bearing with a captured bearing/race and axle retainer. where it could be an issue is if you have to turn down the chromoly shaft to fit the new bearing.

Who still makes one of these for the 35?

 

[mrblaine]

would a C-clip eliminator not solve the problem? I believe it replaces the outer bearing with a captured bearing/race and axle retainer. where it could be an issue is if you have to turn down the chromoly shaft to fit the new bearing.

A C-clip eliminator would solve that problem or did when Superior still made the one I built for them. It converted the Dana 35 to use TJ style set 10 bearings and shafts with a 100% bolt on housing end. Unfortunately, it only worked with drum brakes and they (Superior) are not around. It did however, work perfectly.