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How to build a cheap Dana 30 for 35s


Justin Homan

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So my Jeep is currently on 33’s and id like to go to 35’s soon. My current setup in my 30 is stovk everything with a Spartan locker and 4.56 gears. I like to wheel my Jeep so i want to make it tough enough for 35’s. My current list would be a truss, probably from jcr some c-gussets and a set of chromoly 27 spline shafts. Is there anything else ill need to do to make it work? The rest of the Jeep is already set up for 35’s.
 

LieutenantJohnson

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Should be able to do it with just upgraded pads/rotors. I have upgraded to better pads / rotors on both jeeps and I towed a 1000# Tent trailer with no issues.

I slapped in a HP30 in my 97TJ. Never had an issue on 36s, aussie locked. No brake or shaft upgrade. For almost 7 years. If you can get your hands on a cheap HP30, it will be direct bolt in besides re-gearing and moving Spartan over. Worth it IMO. To get reverse cut stronger gears, larger ABS shafts (which you can put on a D30 too) and the HP which gives you better angles on the front shaft
 
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Justin Homan

Justin Homan

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Looks lime the general consensus is brakes and shafts and maybe c-gussets. I already got a good set of brakes so some shafts and she should be good for them 35s
 
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LieutenantJohnson

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Yup what Jivw said. No gussets, no trusses. Truss me :)

Keep an eye out for a HP30 in the future. They are EVERYWHERE from XJs and cheap or free
 
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Jerry Bransford

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No gussets or trusses are needed to run 35's all day long on a D30 on very tough trails. Once you add a front locker just replace the shafts with 4340 27 spline shafts and you'll be good to go.

I finally broke a front factory shaft with 35's and lockers on a VERY tough trail (Sledgehammer in Johnson Valley CA) but never had any more problems with my D30 after installing 4340 27 spline shafts with Spicer 5-760x u-joints.
 
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Vasq

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Give John at Auburn Car Repair and OffRoad a call.
Does he keep them in inventory or is that a custom shop sorta thing? thanks for the tip!
there are 5 'Rokees right now at pick a part about 20min from the border at Sumas, WA
Huh, i'll have to check them out. I've scowered some local junk yard within an hour-ish of me but they either wanted way too much or the housing was damaged.
 

Vasq

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He just usually has that kind of stuff laying around, he may have one or so, may not but he’s usually worth a call.
Thanks! i'll shoot him a call.
On a side note Mumble, did you do your own gears or did you have them done? I see they also do gears.
 

Mumblewood

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Renton Wa
Thanks! i'll shoot him a call.
On a side note Mumble, did you do your own gears or did you have them done? I see they also do gears.
Haha I haven’t done gears yet, that’s why I can’t go much above 65-70ish, (5 speed manual with 4.11’s and 37’s) but with the 4:1 case it runs about perfect for me in 4lo. But when I do do them, I’ll probably just do them myself
 
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