Need to rebuild Dana 35 or possibly upgrade to Dana 44

[dka70]

My first post so want to say hi. Been helping family and friends with their Jeep's over the years and currently working on a other.

2001 Wrangler X 4.0, 5sp, 4:11, Dana 35 with broken ring and spiders. If we end up with keeping the 35, what gear manufacturers are gtg? I've had good success using Yukon with GM's, but never rebuilt a Dana. I know the 35 is weak, but want to be sure the hardware we get is good.

If we do find a Dana 44, what years are a direct swap? Does the brake line clamp and vent tube all mount the same? The TJ has drum brakes, so are the Dana 44's drum or disc? Is that year dependent?

All input appreciated.

 

[machoheadgames]

Revolution is the go-to gear manufacturer around here. In some ratios you can still find Dana factory level gears, but they aren’t common. Are you looking to regear or just fix the 4.11s?

My guess is your spider gears broke into chunks and then grenaded the ring gear by lodging into one of the teeth. I feel like for spider gears, the upgraded 707321x kit is the best option. They are stronger than stock being forged, and won’t pit like the stock gears. Probably won’t break either.

If you decide to do the Dana 44, 97-02 are all drum, 03-06 could be disc or drum. If it is from an 03-06 Rubicon or Unlimited, it’ll be a disc 44. Not that it really matters, but 97-02 will be shimmed under the carrier bearings, whereas 03-06 have thick perfect width shims outside of the carrier bearings.

If you get a Dana 44, you’ll need to regear it to match unless you can find one out of a Rubicon. With those, you need to pay attention to the locker and make sure it’s not broken. The LSD side of the locker likes to break.

 

[dka70]

Are you looking to regear or just fix the 4.11s

Keep the 4:11

My guess is your spider gears broke into chunks and then grenaded the ring gear by lodging into one of the teeth

Yeah, I agree.

Thanks for the info, I will look into the Revolution hardware.

 

[dka70]

Looking at Revolution's site, they don't seem to list the 4:11, but a 4:10..unless I missed something.

The Dana 35 I'm working on has a 37T ring and a 9T pinion.

 

[machoheadgames]

Looking at Revolution's site, they don't seem to list the 4:11, but a 4:10..unless I missed something.

The Dana 35 I'm working on has a 37T ring and a 9T pinion.

It won’t matter. I haven’t looked in a while but I think they are actually 4.11 (37,9), but even if they were 4.10 (41,10), it would be fine. The front is 4.10 so I’m factory form they aren’t matching anyways.

 

[dka70]

The front is 4.10

That's interesting, I understand that it won't matter too much, at least they will match afterwards.

I want to add that the rear upper control arms are adjustable, not sure what make/model these are but the center needs replacing and it appears there's a snap ring holding it in.

Any idea which arms these are? Worst case we will just replace the pair.

 

[TheBoogieman]

RE arms.

 

[John Cooper]

I wouldn't try and rebuild that, looks like it's lived up north or swam in the ocean!!!!

Check out Core 4x4 control arms.

 

[cmoore]

If the interest is keeping it a long time,
ECGS has decent price on complete axle replacement. It’s not always cheaper to replace the whole thing but a bolt in axle can have fewer rabbit holes to fall down. https://eastcoastgearsupply.com/i-1...j4xDGWBQTaEyUai4ugdidtZtsqMzY84tWFSE4-0&gQT=2

If you can weld, some Ford Explorer 8.8 axles came in a 4.11 w/disc brakes. IDK anymore but they used to be easy to find in yards and Barnes has a bracket kit. https://barnes4wd.com/products/jeep-tj-or-lj-ford-8-8-swap-kit-with-truss

Im guessing you know this, but of course with any axle change, dont forget to check driveshaft lengths.

Good luck with the project.

 

[machoheadgames]

That's interesting, I understand that it won't matter too much, at least they will match afterwards.

They might match, if Rev’s gears are actually 4.10. I’m not sure they are. They very well could be 4.11 like stock and be listed incorrectly. I’ve had a pair in my hands before but I forget what they were.

As for the arms, I didn’t know what they were but looks like others did.

 

[macleanflood]

I'd throw a Super 35 kit and an e-locker at that Dana 35.

-Mac

 

[NashvilleTJ]

I'd throw a Super 35 kit and an e-locker at that Dana 35.

-Mac

Why do I think that if you did that, it would leak....



(Sorry Mac - Couldn't resist )

 

[macleanflood]

Why do I think that if you did that, it would leak....

Absolutely!

To @dka70 we're talking about my Chasing 231J leaks thread and my complete and my serial failures at keeping ATF in the box.

But back on topic I run a super Dana 35 with upped spline count shafts from Revolution, and an Eaton e-locker. Generally regarded as being pretty damn to close to a 44 in terms of strength.

And despite my ability to break just about everything I only grenaded my gear setup once! It's been working perfectly on my second try for years... which generally is good for me since it typically takes me 4-5 attempts to get something to work.

-Mac

 

[RHanna]

Rubicon express

 

[TheBoogieman]

looks like it's swam in the ocean!!!!

Or an Alabama puddle. Mr. Cooper would know about that.

 

[RHanna]

Why do I think that if you did that, it would leak....



(Sorry Mac - Couldn't resist )

Every time I see you’ve commented on a thread like this I expect
Tons and fourties’

 

[TheBoogieman]

RE arms.

Rubicon express

 

[NashvilleTJ]

Every time I see you’ve commented on a thread like this I expect
Tons and fourties’

Yeah, I really missed my opportunity given the thread title...

 

[TheBoogieman]

Every time I see you’ve commented on a thread like this I expect
Tons and fourties’

I've heard @NashvilleTJ prefers double D's over 4Ds. Also, he likes things made in Japan I believe.

 

[NashvilleTJ]

RE arms.

Rubicon express

Yup. You can tell they are RE arms by where they bend...