Help me build a Super 35

[RYAN17]

Okay so ive had my tj for a year now and love it to death. Started off by pouring my money away with all the flashy mods that i thought were so cool at the time (headlights, LEDs, front bumper) but now im starting to upgrade things that matter and i need some help. Right now I have a 4 inch suspension lift on 33’s. Its a complete dog on the highway and im pretty sure im on stock 3.07 gears. Enough to make you hate driving remotely up hill. Anyways im looking to build a super 35 after being steered away from the 8.8 and now im seeing that the Dana 35 is just a better way to go (in my opinion). The only issue is that I have no clue how to buy exactly what I need to do the build. I would like to know what you recommend and possibly link me to what i will need to complete the job.

FYI... running 33’s with an automatic (maybe 35’s way down the line when my 33’s have no more life in them) So what gearing should I be looking at? and preferably a selectable locker? Because im in icy climate half the year

 

[xxdabroxx]

Which automatic do you have?

 

[Chris]

Which automatic do you have?

According to his profile, a 42RLE.

 

[Chris]

First you'll need a Super 35 kit:
https://www.4lowparts.com/shop/super-35-rear-axle-kit-dana-35-30-spline/
That is 30 spline (which you want), but since your stock differential is 27 spline, you'll need a new diff. This would of course be the perfect time to put in a locker (I would suggest an ARB), so get one with 30 splines.

In addition, you'll want to re-gear at the same time. For your 33s (or 35s) you'll want 5.13 gears, which is as deep as you can go in the stock axles anyways (see this thread for more info: What gear ratio should I install in my Jeep Wrangler TJ / LJ? (and other re-gearing FAQs)).

So basically, Super 35 kit, locker, and gears is what you'll need.

 

[tworley]

With a Detroit Locker
https://www.4lowparts.com/shop/super-35-rear-axle-kit-detroit-locker-revolution/
With an ARB locker.
https://www.4lowparts.com/shop/super-35-rear-axle-kit-arb-air-locker-Dana 35-30spl/
I am a fan of ARB. The only issue I have had is an air leak at the solenoid. The air compressor does not come in the link above, but you can find a compressor to actuate the lockers for roughly $150

 

[RYAN17]

https://www.4lowparts.com/shop/super-35-rear-axle-kit-arb-air-locker-Dana 35-30spl/
Does this kit include the gears also?
I didnt really understand the websites description.

 

[Hook_62]

https://www.4lowparts.com/shop/super-35-rear-axle-kit-arb-air-locker-Dana 35-30spl/
Does this kit include the gears also?
I didnt really understand the websites description.

Ring and pinion, no, that is separate. Don't forget you have to get the same gear ratio for the front diff also.

 

[MallCrawlOnTons]

I don’t know what kind of money you want to spend. But if your ona budget get a set of gears first and foremost. You’ll enjoy the Jeep much more.

 

[RYAN17]

Im thinking about regearing first and then saving some dough to do the super 35 because im still a student and I need an SYE because of the previous owners t case drop. Anyone think this is the right move? And can i reuse my new gears once i do the super 35?

 

[Hook_62]

Yes, what you are doing is correct and a good idea. Keep in mind that if you truly do have 3:07 gears the carrier break will limit what gears you use on that particular carrier. Read this article: https://www.crawlpedia.com/thick_gears.htm
You are going to do a super 35 so that takes care of the rear carrier, but you can't use the gears you buy for your current carrier and use them in the super 35 because of the carrier break. Unless you get "thick".

Dana 35

3.31 & Down

3.54 & Up

Article will explain. Has a chart of each diff. carrier break. As Chris stated you want 5:13 or at a minimum 4:56 gears with 33" tires.

I am currently in the same position as you, stock 35 on 33"-12.5 tires, 1.5" TC drop. But mine has 3:73's. I bought it this way, so I don't know how long these tires have been on it. That said this is what happened to my carrier due to tire size. Could have been something else, but I'm betting it was tire size and too many years on them. this just happened a few weeks ago, so, it is now on jack stands waiting for this big windfall of $$$ to come in that I may repair it and do it correctly with the SYE, get rid of TC drop, control arms,,, shit where does it end.

I'm going Dana 44, found one in a junk yard with Tracloc. Will have a nice empty 35 case, in good shape for sale soon.

Edit: just noticed in the article I posted, these guys have there "higher and lower" definitions wrong or backwards, this is addressed in the 1st comment below the article.

 

[Fouledplugs]

Yes, what you are doing is correct and a good idea. Keep in mind that if you truly do have 3:07 gears the carrier break will limit what gears you use on that particular carrier. Read this article: https://www.crawlpedia.com/thick_gears.htm
You are going to do a super 35 so that takes care of the rear carrier, but you can't use the gears you buy for your current carrier and use them in the super 35 because of the carrier break. Unless you get "thick".

Dana 35

3.31 & Down

3.54 & Up

Article will explain. Has a chart of each diff. carrier break. As Chris stated you want 5:13 or at a minimum 4:56 gears with 33" tires.

I am currently in the same position as you, stock 35 on 33"-12.5 tires, 1.5" TC drop. But mine has 3:73's. I bought it this way, so I don't know how long these tires have been on it. That said this is what happened to my carrier due to tire size. Could have been something else, but I'm betting it was tire size and too many years on them. this just happened a few weeks ago, so, it is now on jack stands waiting for this big windfall of $$$ to come in that I may repair it and do it correctly with the SYE, get rid of TC drop, control arms,,, shit where does it end.
View attachment 105933
I'm going Dana 44, found one in a junk yard with Tracloc. Will have a nice empty 35 case, in good shape for sale soon.

Edit: just noticed in the article I posted, these guys have there "higher and lower" definitions wrong or backwards, this is addressed in the 1st comment below the article.

Stock Dana 35 on 33’s and this happened? What were the factors that lead to the break? Were you wheeling it “hard?”

 

[Hook_62]

Stock Dana 35 on 33’s and this happened? What were the factors that lead to the break? Were you wheeling it “hard?”

Was pulling out of my driveway, going to pick up my daughter. Uphill and had a sudden loss of power, only for a second, then a nice bang, nothing but rev and grinding. Put it in 4H to get back to the house.

 

[mr_sparkle]

@RYAN17 I have a set of Revolution Gears for a Dana 30/Dana 35 that are 5.13 ratio. PM me if you want to discuss.