Looking for suggestions on strengthening my Dana 35 axle

Lorenzo Altarocca

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Jul 14, 2021
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46
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Roma, Italy
Sunday wheelin ended up with this:
broken rear left axle (Dana 35) !

Sounds strange for a 4.0L with 2inches lift and 31” Cooper tires (lsd rear).
It happened on a long climb on light/medium rocks with 4 people and bags inside.
No bouncing, no full throttle, just heavy load and not the best grip cause I did not deflated tires, damn.

Suggestions for an improvement?
I’m looking to regear the Jeep too and maybe going to 33s.
Hating those c-clips !!!!!

I'm thinking about going with 1541H axles and mantain the c-clips and no more than the LSD at the rear.

(Just repaired it yesterday with another used axle and a new oil seal after a big flush inside with no differential)

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1541H 30 spline axle shafts would be a great choice. They require a 30 spline carrier too which means a locker like an Eaton E-Locker, ARB Air Locker, or Detroit Locker.

Www.revolutiongear.com is a great source for those kits, they are called a Super 35 Kit. Avoid any advertising 4340 or 4140 chromoly shafts which are not suitable for a Dana 35.
 
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If it's not fixed on the trail, normally like this.... Something strapped to the frame to hold the broken shaft inside the axle tube so it can be driven.
How did you get off the trail with the broken axle?
1km of trail up and down on rocks this way.. 3 hours!
Then tow truck when finally out of trail.

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1541H 30 spline axle shafts would be a great choice. They require a 30 spline carrier too which means a locker like an Eaton E-Locker, ARB Air Locker, or Detroit Locker.

Www.revolutiongear.com is a great source for those kits, they are called a Super 35 Kit. Avoid any advertising 4340 or 4140 chromoly shafts which are not suitable for a Dana 35.
As an mech engineer, with those axles riding into the bearings I'd avoid 4340 or 4140 for sure.
What about an easy swap with 1541H but 27 spline? Do you think is ok with lsd rear and 33s ?

I have already bought carriers for 3.55up (front open and rear with LSD) in order to go to 4.56 (my plan is 33s) but I'm seriously thinking about 30 spline now...
 
I thought maybe he used a RE’MO and a FO’RCOL 😂
Huh?
As an mech engineer, with those axles riding into the bearings I'd avoid 4340 or 4140 for sure.
What about an easy swap with 1541H but 27 spline? Do you think is ok with lsd rear and 33s ?

I have already bought carriers for 3.55up (front open and rear with LSD) in order to go to 4.56 (my plan is 33s) but I'm seriously thinking about 30 spline now...
You should be fine with 33's and LSD like a Truetrac with 27 spline 1541H shafts.