Time to get rid of the Dana 35

[machoheadgames]

Interesting plan, I am not a huge automatic fan but have a few thoughts/questions to consider.
Does the 42RLE have a locking torque converter ? And if so does it lockup in 3rd gear if OD is shut off?
If the TC isn't locked will the trans run extremely hot at crusing speeds in direct 3rd. gear ?
Maybe an automatic fanboy can weigh in on these concerns.

I like the concept of compensating a work around for dealing with the Bonneville approved OD ratio in a Jeep.

Yes, the TC is lockup style. It locks up in 4th for sure and it is supposed to lock up in 3rd when OD is disabled. I have seen members here post that it does lock up in 3rd (people were concerned about towing in third over long distances) and I believe where that came from was the FSM and people watching the tach gauge in their own Jeeps. I can check an FSM to make sure.

If the TC didn't lock, then yes it would be a problem. In the old days (early 90s and prior) most vehicles shipped with non lockup converters but the non locking converters were built a bit differently to handle that extra heat and constant slippage, so they were performing to their design criteria and it was fine (other than the extra mpg loss and noise due to the engine running at a higher non-locked RPM. I believe it is more critical that a lockup converter needs to actually be able to lock up or else it will generate a lot of heat and won't last as long since it wasn't designed to constantly slip.

I have seen it confirmed by members that their 42 locks up in third when they turn off OD so it should not be an issue at all.

 

[machoheadgames]

Interesting plan, I am not a huge automatic fan but have a few thoughts/questions to consider.
Does the 42RLE have a locking torque converter ? And if so does it lockup in 3rd gear if OD is shut off?
If the TC isn't locked will the trans run extremely hot at crusing speeds in direct 3rd. gear ?
Maybe an automatic fanboy can weigh in on these concerns.

I like the concept of compensating a work around for dealing with the Bonneville approved OD ratio in a Jeep.

Boom! (from FSM)

TORQUE CONVERTER CLUTCH (TCC)
The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased.

So yes, all good to run in 3rd 24/7 with no heat issues whatsoever.

 

[ColoJeep]

Boom! (from FSM)

TORQUE CONVERTER CLUTCH (TCC)
The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control (TCC) solenoid on the valve body. The torque converter clutch is controlled by the Powertrain Control Module (PCM). The torque converter clutch engages in fourth gear, and in third gear under various conditions, such as when the O/D switch is OFF, when the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased.

So yes, all good to run in 3rd 24/7 with no heat issues whatsoever.

Thanks! machoheadgames , It is great to get a qualified opinion backed up with the FSM !
My automatic days were in Aluminum P.G. with rear pump, THM 350 , and THM 400 , so no lockup TC or OD.
Since I run AX-15 , NV 3550 , and CH465 in my rides none of this applys to me .
However I would hate to see someone fry their juice trans. by doing the wrong thing! Thanks again

 

[thekevin]

Well this is all good news. I looked around last night and it looks like the Revolution Super35 kits are sold out everywhere. I do see some Ten Factory kits with Powertrax Griplok lockers for a good price though.

 

[Zorba]

Well this is all good news. I looked around last night and it looks like the Revolution Super35 kits are sold out everywhere. I do see some Ten Factory kits with Powertrax Griplok lockers for a good price though.

Welcome to Joe Biden's Amerika. Lots of things are unavailable or 'on backorder'. I'm waiting for H&R springs to re-appear...

 

[thekevin]

No kidding, by the time stuff is available again it will be illegal to modify your vehicle.

 

[starkey480]

Yukon sells 1541h super 35 shafts I believe

 

[SvtLdr]

Well this is all good news. I looked around last night and it looks like the Revolution Super35 kits are sold out everywhere. I do see some Ten Factory kits with Powertrax Griplok lockers for a good price though.

Have you looked into piecing the kit together yourself? Buying a 30-spline locker and the 1541H shafts separately?

 

[Jerry Bransford]

Well this is all good news. I looked around last night and it looks like the Revolution Super35 kits are sold out everywhere. I do see some Ten Factory kits with Powertrax Griplok lockers for a good price though.

Call Revolution and ask for Brook Hilton, or I guess anyone there will be fine. I had an email conversation with him and they were starting to get axle shafts back in stock. I dunno if that includes the 1541H 30 spline shafts for a Dana 35 but it's worth a call.

 

[FarminAg]

Call Revolution and ask for Brook Hilton, or I guess anyone there will be fine. I had an email conversation with him and they were starting to get axle shafts back in stock. I dunno if that includes the 1541H 30 spline shafts for a Dana 35 but it's worth a call.

Why do you like the 1541s over the chromoly shafts?

 

[machoheadgames]

Why do you like the 1541s over the chromoly shafts?

chromoly (4340, 4140, etc) should not be used in a Dana 35 due to its hardening properties. The Dana 35 wheel bearings are roller style and roll directly on the axle shaft rather than being pressed onto the axle shaft with an inner race like Dana 44 bearings. If chromoly shafts are not hardened just perfectly, the Dana 35 roller bearings woild wear a groove into the shaft. 1541H is a case hardening alloy which will work fine with roller bearings.

 

[JMT]

I have some money set aside to do some upgrades on my TJ and first off is getting rid of the Dana 35. It's an 03 4.0/42RLE/3.73s/31x10.50s right now. I have fairly new 3" BDS springs so I think I am just going to go to 33's. I am wanting to get some input so I can get my money spent in the right areas.

Right now I have tracked down a couple of rear axles that are close enough for me to get.

$1250 - Dana 44 3.73s - would have to regear and put a locker in
$1550 - 8.8 4.88s - already set up for a TJ and has factory limited slip

I would also of course be regearing the Dana 30 up front and plan on going with a lunchbox locker in it.

Another option is I found for $2800 an 8.8 with 4.88s and limited slip and a HP Dana 30 4.88s and a locker already in it that is all ready to bolt right in.

I am pretty handy and have a ton of tools but I don't weld and I don't do gear swaps.

View attachment 265570

Don’t see why you need to get rid of the Dana 35 due to 33’s. That axle is fine. Just S35 the rear and lock the front with 4340 Chromoly shafts

 

[Jerry Bransford]

chromoly (4340, 4140, etc) should not be used in a Dana 35 due to its hardening properties. The Dana 35 wheel bearings are roller style and roll directly on the axle shaft rather than being pressed onto the axle shaft with an inner race like Dana 44 bearings. If chromoly shafts are not hardened just perfectly, the Dana 35 roller bearings would wear a groove into the shaft. 1541H is a case hardening alloy which will work fine with roller bearings.

That is exactly right and here's a photo of a 4340 shaft after being placed into a Dana 35. You can see where the Dana 35's outer bearings wore through the surface of the shaft due to insufficient surface hardening of a 4340 or similar chromoly shaft.

 

[eastbloc]

With decades worth of shit about Dana 35 that is floating on internet, it is no wonder that 8.8 makes it to the top of alternatives.
Once people calm down, educate themselves about shortcomings of stock Dana 35 and issues associated with 8.8 swap, the mighty Dana 35 turd all of the sudden becomes a golden nugget.

On other hand, when you can grab a fresh Dana 44/489 from ECGS or equivalent, for only $1000 more compare to $ it would take to upgrade Dana 35 into S35, lots of thinking arises

 

[Jerry Bransford]

With decades worth of shit about Dana 35 that is floating on internet, it is no wonder that 8.8 makes it to the top of alternatives.
Once people calm down, educate themselves about shortcomings of stock Dana 35 and issues associated with 8.8 swap, the mighty Dana 35 turd all of the sudden becomes a golden nugget.

The 8.8 toppled out of the top of the list of alternatives years ago, it ultimately proved to not be a great choice. Too big of a pumpkin, reduced ground clearance, a c-clip design, and its pinion shaft is offset to the side causing the driveshaft's rear u-joint to have to work through two angles. Not to mention not many Jeepers are capable of converting it for use in a TJ and the costs of doing that are not cheap.

 

[FarminAg]

chromoly (4340, 4140, etc) should not be used in a Dana 35 due to its hardening properties. The Dana 35 wheel bearings are roller style and roll directly on the axle shaft rather than being pressed onto the axle shaft with an inner race like Dana 44 bearings. If chromoly shafts are not hardened just perfectly, the Dana 35 roller bearings woild wear a groove into the shaft. 1541H is a case hardening alloy which will work fine with roller bearings.

Thankyou for the great explanation.

 

[FarminAg]

Don’t see why you need to get rid of the Dana 35 due to 33’s. That axle is fine. Just S35 the rear and lock the front with 4340 Chromoly shafts

Does a dana 30 have roller bearings like a Dana 35 to wear in to chromoly shafts? I'm learning 1541H is better for the rear if doing a S35 kit.

 

[Chris]

The 8.8 toppled out of the top of the list of alternatives years ago, it ultimately proved to not be a great choice. Too big of a pumpkin, reduced ground clearance, a c-clip design, and its pinion shaft is offset to the side causing the driveshaft's rear u-joint to have to work through two angles. Not to mention not many Jeepers are capable of converting it for use in a TJ and the costs of doing that are not cheap.

There’s absolutely no point in an 8.8 whatsoever. If you can wheel a Super 35 with 35” tires in some of the toughest terrain in the state, then I see no point whatsoever in an 8.8.

 

[Jerry Bransford]

Does a dana 30 have roller bearings like a Dana 35 to wear in to chromoly shafts? I'm learning 1541H is better for the rear if doing a S35 kit.

No, a Dana 30 doesn't have outer bearings like a rear shaft does, it uses a unit bearing hub. 4340 is fine in a Dana 30.

 

[FarminAg]

There’s absolutely no point in an 8.8 whatsoever. If you can wheel a Super 35 with 35” tires in some of the toughest terrain in the state, then I see no point whatsoever in an 8.8.

No, a Dana 30 doesn't have outer bearings like a rear shaft does, it uses a unit bearing hub. 4340 is fine in a Dana 30.

noted!