The Difference

uvalax236 · **Posted:** Wed Oct 19, 2005 9:43 am

What is the main difference between a Dana 35 and a Dana 44? I know one is stronger but what makes it stronger? The axle shafts? Axle Housing? Thanks!

kevh · **Posted:** Wed Oct 19, 2005 10:22 am

the shafts on a 44 are quite a bit bigger. one of the main differences is also that a 35 is a c-clip axle (like the 8.25, but the 8.25 is stronger than a d35). small c-clips hold the shafts in. when the shafts break, it is always at the c-clip. the end of the shaft usually mushrooms out when it breaks making it really difficult to get out. this is a pretty common problem on lifted/locked cherokees and yjs,which is why most d35s get replaced for a 44s, ford 9" or even d60s.

the1jferg · **Posted:** Wed Oct 19, 2005 10:48 pm

I'll consider myself the unfortunate resident LIBERTY Dana 35 Expert until proven otherwise. I wish I wern't!!!

The Dana 35 on the Liberty is NOT a C-clip axle and the shafts and other parts were beefed up (stronger) than the C-clip versions.

Seems Dana went back to the old style Non C.

YOU CAN TRUST ME ON THIS ONE. I've been in this rear more times than you can count!!! I've had the axles, carrier, and all out several times too. IT still SUCKS (to me) because of the ABS tone ring issue there ain't enough quality streetable options.

I have tried to break it or my powertrax, and continue to try EVERYDAY!! So far I'm suprised it ain't broke.

Early 2006 Aurburn is coming out with a LSD/Electric locker for it and milled for ABS ring. I'm waiting??

The Dana 35 has more tube flex than other ones, there is a cure for that with some U bolts and long piece of hitch steel made to fit. It stiffin'z it up.
Or you can buy this axle truss: http://www.4x4wire.com/jeep/reviews/super35truss/

I don't know if this is the trend with all new 35's or just the Liberty.
http://www.theautochannel.com/news/2001 ... 19707.html

I can't verify this tidbit: I even talked to DANA in 2003, they told me "you'll usually only find the Dana 35 on the early (pre-low) liberties". Dana calls it a "Super 35" and said its "way stronger than the 8.25 and other 35's because of the new metal alloys in the componets and shafts". they said "Jeep did not want to foot the bill for these since the majority of liberty's end users were "grocery store" haulers"

If this is true, and the stronger Tranny on early models is true. It would show they had beefier intentions until they found the target market.

Thats not to insult anyone...WE are the minority.

http://www.thefergusons.us/kj/kj.htm

Need more info? :cry:

kevh · **Posted:** Thu Oct 20, 2005 2:29 pm

well, some of it is still true

didnt know they went back to a non c-clip version, about time. makes sense though since the 35c (c was for "custom", not "c-clip") was originally only meant to be put behind the puegot tranny in the yj and then later in the cherokee.

either way, still not as strong as a 44. without the c clips it would definitely be perferrable over a 8.25 though. no matter which version you get you are still stuck with 27 spline shafts and the small joints

i cant see them trying to call it a "super 35" though since that is a product that has been offered by superior gear for a long time now. it is basically a d35c with upgraded axle shafts (30 spline vs. the stock 27 spline), r&p, a full detroit, etc. nice kit, but costs quite a bit of $$

your powertrax should be fine since it is rated up to a 32" tire if i remember right (most of the lunch box lockers are). anything over that and you would be asking for a blow up.

the1jferg · **Posted:** Thu Oct 20, 2005 2:46 pm

I just thought I'd post anything I had on it.

Yes, I knew of the Super 35 kit and the axle truss when I talked to them, I was suprised they used that term. Thats why I had them elaborate while playing semi-dumb.

"it would definitely be perferrable over a 8.25" You are only the second person to say that. The first being DANA.

KevH, I'm still working on this tact thing. I did not mean to be harsh when I said "it was not true". Most folks don't know about the change.

All my Love

kevh · **Posted:** Fri Oct 21, 2005 12:34 am

lol...no prob

the more info the better. heck i didnt even know they put a d35 under a liberty until this thread

FreedomKJ · **Posted:** Fri Oct 21, 2005 1:25 am

kevh wrote:

lol...no prob

the more info the better. heck i didnt even know they put a d35 under a liberty until this thread

All 4cyl KJs (and at least one 6cyl) have D35s in the rear.

Jeepjeepster · **Posted:** Fri Oct 21, 2005 3:45 pm

im alittle confused, ur telling me the d35 is stronger than the 8.25 in the libbys?

the1jferg · **Posted:** Fri Oct 21, 2005 5:45 pm

I ain't touchin that one.

I guess the debate would be over the non-c dana 35 -VS- 8.25

This I'm not an expert on.

kevh · **Posted:** Fri Oct 21, 2005 10:08 pm

k, i guess i am a glutton for punishment...

we kinda need to compare apples to apples here.

the 8.25 in the libby is a c-clip rear end but it does have 29 spline (larger) axles

the dana 35c (common to the cherokee and yj) is a c-clip axle but only has 27 spline (smaller) axles

so, in this case i would say the 8.25 is stronger because of the larger axles.

now if the d35 in the libby is non c-clip, it is kind of a wash. the d35 in the libby will not have the weak area where the axles "neck down" for the c-clip, but on the other hand, the d35 will still have smaller axles (27 spline vs 29 spline in the 8.25). if dana is now using an updated axle in the d35, that would also have to be taken into play

so one has larger axles, but the other doesnt have the c-clip problem. the larger axles is why the 8.25 shows up in the 6 cylinder (jeep reasoning...more power, larger axles needed)

but wait, there is good news...unless you are running at least a 35" tire or really low (numerically higher) gears, you have nothing to worry about. since a 31-32" is about as big of a tire as most of us (sfa guys aside) can run, we should all be ok. i have seen xjs and yjs on 33s (and even some on 35s) with heavy footed drivers last a forever.

the1jferg · **Posted:** Fri Oct 21, 2005 11:38 pm

I do know that if you put enough torque on any axle in a bind it will pop no matter the tire size.

Again, Dana told me that the shafts for this Non -C 35 are made out of a stronger alloy.

I can't verify, I just listened.

These to:

Has larger pinion stem and bearings for enhanced NVH characteristics, and net-formed differential gears for increased strength and durability.

The driveshafts, a combination of Spicer(R) 1310 and 1330 Series steel, rear main assemblies, feature Spicer Life(TM) maintenance-free, universal joints.

"Dana will also provide Spicer independent front and beam rear axle
assemblies, offering a wide range of enhancements. These improvements include an all-aluminum carrier and tube for improved fuel efficiency"

I'm not sure if they are saying the 35 is aluminum? I'll put a magnet to it.
Come to think of it, it does look somewhat aluminum???

This aluminum carrier and tube alone would account for the NOISE transfer of my powertrax!!!

kevh · **Posted:** Sat Oct 22, 2005 12:12 am

yepper...the front is supposedly aluminum. now, in a perfect world, since it is tucked up and out of the way, it should be fine but i know a few here have already blown them up

which of course is not good

the1jferg · **Posted:** Sat Oct 22, 2005 12:23 am

My 35 ain't aluminum, Thats good

FreedomKJ · **Posted:** Sat Oct 22, 2005 1:00 am

An aluminum solid axle would never work, at least not without rediculously thick tubes. The front housing and tubes can be aluminum because they don't have to support any weight.

Not that I doubt Dana told you the D35 in the KJ is stronger than the 8.25", but I'd say that's just them wanting to sell more axles. Think how much more money they'd make if every V6 KJ had a D35 instead of an 8.25".

The fact that the front housing is aluminum isn't nessecarily the reason some people have grenaded them. It appears to at least a few of us that it may be a manufacturing defect. Granted we've seen a few of them around here (I think about 10-15 maybe,) but there's quite a few of us and we're probably more abusive on our Jeeps than the average KJ owner. If it were a design problem I'd think we'd have seen more cracked housings.

the1jferg · **Posted:** Sat Oct 22, 2005 10:24 am

Make no mistake...I wish I had the 8.25 for option sake only. If Auburn comes through for me on the LSD/electric locker then I'll take THIS version Dana 35 over the 8.25 any day of the week.

The only thing I can verify out of all the crap I've gathered is the Non-C aspect.

This is good for me because my wheel and tire won't be in the street when I break it. I think a C-axle can slide out of the tube when it breaks.

camper · **Posted:** Sat Oct 22, 2005 2:38 pm

dana 35 axle.....1.18" dia. axle shaft...27 spline....7 9/16 inch ring gear....

corp. 8.25 axle.....1.21" dia. shaft...29 spline....8 1/4 inch ring gear.....

dana 44 axle....1.31" dia. shaft....don't know spline count....8 1/2 inch ring gear....

i believe the corp 8.25 has 3" dia. tubes which I think are the largest of the three axles above...

I've been scanning the different jeep forums looking for this kind of information....wrote the above down one night from a discussion on the web....the fellow sounded like he had it clear.....but I haven't found a single source of sizes and expertise I can trust....people don't mean to give bad information but you can't take for gospel anything you read on these places....so somebody check me too....

slightly changing the subject....

on jeepforum.com, I asked a certified jeep tech about the front d30a....he said chrysler is phasing out dana/spicer axles and will go to all chrysler corporation axles over the next few years....again this is just a comment on the internet....doesn't specifically say about the TJ, etc...

"I meant that Chrysler has parted ways with Dana and their products will slowly disappear. Currently the only production vehicles to still have Dana axles are the front in the Liberty and the 2500 and 3500 Ram Truck front axles. Everything else has switched over to corporate or American axles. Mostly corporate 8.25, 9.25, 11.5 and 12.5 (I think those are right) Chrysler vehicles have been changing so fast I've been having a hard time keeping up. I used to know these things inside and out. I would imagine that the Liberty will be getting a smaller version of the front axle used in the light duty pickups and the Grand Cherokee (WK).
__________________
Dodge/Chrysler/Jeep Technician 11 Years
ASE Master Certified
L1 Advanced Engine Performance

the original question on this thread was a good one....kevh, if you're the man for this topic....give it to us.....dana 30 specs...dana 44.....dana 60....semi floating vs. full float...

for my money, this is what I want on this forum....(by the way jferg, I'm a member of no-tact club myself... :roll:

)

the1jferg · **Posted:** Sat Oct 22, 2005 6:19 pm

"Its begining to look a lot like Christmas"

A tow truck yard a mile from my house has a wrecked 03 liberty with 8.25 corp axle with drum brakes...YIPEEE.

The great part: The owner was a true irresponsible citizen without car insurance, owes way too much at the bank, the bank don't want it...and you folks know how tow companys are...I made them an offer. :lol:

kevh · **Posted:** Sun Oct 23, 2005 2:43 am

here are the specs for the standard rear applications. when used up front they often have a lower spline count but everything else stays about the same. the d44 for example can have anywhere form 19 to 30 spline shafts

first our 8.25 for comparisons...

Number of axle splines: 29
Diameter of ring gear: 8.25"
Number of ring gear bolts: 10
Pinion Shaft Diameter: 1.625"
Pinion Splines : 27

standard d30
Number of axle splines: 27
Diameter of ring gear: 7.2"
Pinion Shaft Diameter: 1.375"
Pinion Splines : 26

standard d44 rear
Number of axle splines: 30
Diameter of ring gear: 8.5"
Pinion Shaft Diameter: 1.375"
Pinion Splines : 26

standard d60 rear
Number of axle splines: 35
Diameter of ring gear: 9.75"
Pinion Shaft Diameter: 1.625"
Pinion Splines : 29

i know a comment was made about an aluminum sraight axle not being feasible because of the weight. seems the zj (grand cherokee) came with an aluminum d44 rear. whoda thunk. wonder how strong it is :?:

chefdab · **Posted:** Sun Oct 23, 2005 5:47 pm

That comment about phasing out dana axles might be true. The last time I was at the dealer, I asked if they knew what type of drivetrain the new Wrangler would have and the guy at the dealer told me basically the same thing.

the1jferg · **Posted:** Sun Oct 23, 2005 6:18 pm

They should put the best product in, whatever it is.

The Difference

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