Upgrade to Super 35, or swap to Dana 44?

[mrblaine]

So the deflection, if I was concerned by it, could be remedied via truss, no? Worst-case scenario assumg I can't find a Dana 44 for a good deal and take time to rebuild it how I want...versus the super 35 (which I'm honestly leaning towards anyway)

It isn't much of a concern. It is just an piece of info to show they are not the same housing as reported incorrectly.

 

[Jerry Bransford]

So the deflection, if I was concerned by it, could be remedied via truss, no? Worst-case scenario assumg I can't find a Dana 44 for a good deal and take time to rebuild it how I want...versus the super 35 (which I'm honestly leaning towards anyway)

It's a non-issue, don't worry or even think about it. There are plenty of Super-35 equipped TJs doing extremely difficult rock crawling trails that would scare to death 99% of this forum's membership.

 

[ErikOffroad]

Jerry talked me into a super 35 a couple years ago. I don’t regret it. I’m running revolution 5.13 gears, revolution super 35 kit, and a Eaton e locker. It made sense for me considering I already had the Dana 35 and could regear it my self. I’m on 33 12.5 tires. I personally don’t feel the need to go bigger.

 

[Blackjack]

I have a feeling that in another decade, stupid miss information associated with Dana 35 will die off, and it will go up in value.

Dana 35 and 44 share same housing
Dana 35 smaller pumpkin offers better clearance
Dana 35 smaller ring and pinion is not an issue
Dana 35 axle shafts are a weak point that gets replaced in S35 conversion

Downside of upgrading Dana 35 is its price. Parts and regear job will land you $1000 shy of purchasing a complete axle, to your spec, from somewhere like ECGS. Today you may feel good abut saving a grand, in few month you may wonder why didn't you do it.
If you are planning to get Dana 44 from ebay/craigs/fb - i hope you are able to inspect them well.

As Blaine eluded to the housing is not as strong as a 44. IMO the Dana 44 has better wheel bearings as well lending itself to a higher GVW. Something to consider if you tow or overland with a lot of gear.

It is generally accepted that the Dana 35 RP is one ratio weaker than the Dana 44. IE Dana 35 4.10 gears are the same strength as Dana 44 4.56 gears so this is something that needs to be considered if running very deep gears. The Dana 35 has a couple other weaknesses that need to be addressed as well. First is the ring gear bolts. Early Dana 35 used smaller bolts than the later versions that I have seen back out when running larger tires. So you want to make sure when ordering gears that they have the larger thread or are dual pattern (the better gear brands do this) and drill the carrier if needed. The other is the crush collar. I always use a crush collar eliminator kit. This allows better control over pinion bearing preload and if you have a seal or yoke issue you can make repairs without worry of messing up the preload especially in the field.

 

[RINC]

It's a non-issue, don't worry or even think about it. There are plenty of Super-35 equipped TJs doing extremely difficult rock crawling trails that would scare to death 99% of this forum's membership.

I caved and over paid for a Dana 44. Seeing the video's @starkey480 posted on Youboob, with his super 35, I got tired of shops trying to steer me to a Ford 8.8.

I hope to make up the extra money spent for the Dana 44 by keeping this Jeep for the long term.