Regearing my Dana 30/35

[99AZTJ]

I might as well get my first tech question out of the way. I am currently saving up for the Super 35 kit, but until I can get the full amount, I am currently looking for other options. I know about the D44, but I was wondering about regearing my D35. If I can get my hands on a 4.10 ratio ring and pinion gear set, should I grab it and just regear? ( I've got 3.07s ) Will I need to upgrade my axle shafts to match splines, or will stock be ok? I'm not really too worried about getting lockers yet....I would like to do what I can with minimal cost. They would come out of an OEM 4cyl.
I know that if I do the front, I should do the front to match as well.

I try to do as much research as I can before asking questions, so let me know if I missed out on something important!

[TRLR8TDTJ]

I might as well get my first tech question out of the way. I am currently saving up for the Super 35 kit, but until I can get the full amount, I am currently looking for other options. I know about the D44, but I was wondering about regearing my D35. If I can get my hands on a 4.10 ratio ring and pinion gear set, should I grab it and just regear? ( I've got 3.07s ) Will I need to upgrade my axle shafts to match splines, or will stock be ok? I'm not really too worried about getting lockers yet....I would like to do what I can with minimal cost. They would come out of an OEM 4cyl.
I know that if I do the front, I should do the front to match as well.

I try to do as much research as I can before asking questions, so let me know if I missed out on something important!

The only problem is when you get super 35 kit you will have to pay the labor to setup gears twice.

Kyle

[Fire Ball]

Personally I wouldn't wast the money on a super 35. That is a lot of cash for a turd. I found a cheap axle replacement for mine with 4.56 gears already in it. I re geared the front to 4.56 but I can handle keeping the front D30 for a while. The D35 is really not worth spending that much money on.

As an option I would re gear it if you can get it done cheaply. Then buy some replacement stock shafts for trail spares. I would also see about having a spare carrier and spiders laying around.. It would be a lot cheaper than doing a D35.

I currently run a D35, stock axles on 4.56 gears. I'm locked but I wheel with a soft foot on the skinny pedal. Haven't broken it yet but I have all the spare parts I need to rebuild it including axle tube for almost nothing.

Save your hard earned money to do a D44 or better. Now as far as upgrading the D30, that is an option.

My $.02

[99AZTJ]

Well, if I go with just regearing, I would hold off on the 35 kit. So if I regear, what else will I have to do?
I've also noticed a lot of the front 4.10 gears getting pulled from the new JKs for aftermarkets. Are there any differences between the new and older D30s? Could I use a carrier/set from the JK?

[sunroom2004]

The only problem is when you get super 35 kit you will have to pay the labor to setup gears twice.
Kyle

The differential setup will cost $250 - 350, so it's better to only do it one time when you install the full case locker that comes with the D35.

By the way, you may want to consider the 4.56 ratio with the 33" tires. It will give you a lot more torque at the wheels for highway driving and better crawl ratio off road. I went from 3.07 to 4.56 and didn't lose any MPG.

[terron gregg]

buy a 44

[99AZTJ]

For instance, I was checking out ebay, and I found this:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=200161091381&ssPageName=STRK:MEWA:IT&ih=010

Would this be ok to use in my 99? I'm trying to figure out what I can/cannot use.
I thought about going for the 4.56s, but I was told that the 4.10s would do just fine. I also noticed that they were a little more expensive. I know about the D44s, and how much easier it would be, but I haven't found any yet in my price range. Which is why I'm exploring my options, hehe.
Thanks for all the help so far!

[Fire Ball]

I went from 3.07 automatic to 4.56 on 33's and it is great for wheeling but runs 3100rpm at 60mph. Just a thought.

Since it sounds like you haven't re geared a vehicle before, I would definitely take it to someone who knows what they are doing. Some of the guys here can recommend shops to you. I do my own and I haven't used anyone locally so I can't help you there.

As far as gears and carrier I honestly don't know if older low pinion is the same as the new one. If it is a high pinion, no it won't work.

How long till you can afford to go for the new axle? If you are talking a year or less, just suck it up and save the money.

There are worse things than wheeling on 3.07's. Not many but there are some :D

Do it right once and be done. Get the D44 with a selectable locker like an ARB. I run a lock rite front and rear and I really don't like the lock rite in the back. It pushes me around too much. I will be doing a selectable in my next axle.

[mbuckner]

If you upgrade from a D35 axle, upgrade to Ford 9" axle .......

Then you are set to wheel .......

Best regards,

Mike

[Fire Ball]

I believe the 97 - 04 TJ uses the same gears and carrier according to randy' ring and gear.

[Fire Ball]

D44, F9", 8.8, toyota axle are all good options.

[sunroom2004]

I went from 3.07 automatic to 4.56 on 33's and it is great for wheeling but runs 3100rpm at 60mph.


Hmmm...maybe somebody's speedo gears are off...

I hit 75mph at 3000rpm. :confused:

[Fire Ball]

Yes the speedo gears are still stock, I use my GPS for a speedometer. :D It works out mathematically so I know it is right :)

[99AZTJ]

How long? Well, it could be a month, maybe 4 or 5.....haha, it all depends on what the kids want for Christmas, and their birthdays are in between! I still need to put food on the table, but I'm also just getting restless. I bought a spare set of axles for the 35 a few weeks ago.
And no, I haven't done my own gears. I just don't have enough knowledge in the Jeep world yet! I hope to change all that and learn as much as I can! I'm not afraid to get dirty.

[azcharlie]

Anyone who has regeared and broke a D35 will tell you don't waste your money. Oh wait.......ok I'm telling you don't do what I did. Get a D44 or 8.8 do it right the first time.

[sms1688]

I have a dana 35 locked with 4.88 gears. I havent broke it yet but from what I hear it is going to. I carry spares with me just in case and plan on up gradeing to a 8.8. Just wait and do the upgrade the worst you can do is break the crappy d35 and have to upgrade. Run it till you break it or can afford to get a better rear end behind it.

[YJunk]

I have a dana 35 locked with 4.88 gears. I havent broke it yet but from what I hear it is going to. I carry spares with me just in case and plan on up gradeing to a 8.8. Just wait and do the upgrade the worst you can do is break the crappy d35 and have to upgrade. Run it till you break it or can afford to get a better rear end behind it.


You DON'T want to break that out on the trail unless you know what you're doing and know how to fix it... In theory changing a shaft out is relatively easy, but it can take hours and hours depending on how bad the break was, if any of the peices are jamed up in the carrier, what tools and spares you have etc...

If you're just blasting around the desert with no lockers you're prob gonna be fine; but if you're doing any kind of rock crawling, you're likely asking for a miserable experience (not only for you but also for whoever is with you).

thats my story and i'm sticking to it...

[AZG23]

You DON'T want to break that out on the trail unless you know what you're doing and know how to fix it... In theory changing a shaft out is relatively easy, but it can take hours and hours depending on how bad the break was, if any of the peices are jamed up in the carrier, what tools and spares you have etc...

If you're just blasting around the desert with no lockers you're prob gonna be fine; but if you're doing any kind of rock crawling, you're likely asking for a miserable experience (not only for you but also for whoever is with you).

thats my story and i'm sticking to it...


DING DING DING....we have a winner.....


Its NOT a simple process, and real quick....it can be a nightmare depending on where/when it happens too.

[RokNRich]

You DON'T want to break that out on the trail unless you know what you're doing and know how to fix it... In theory changing a shaft out is relatively easy, but it can take hours and hours depending on how bad the break was, if any of the peices are jamed up in the carrier, what tools and spares you have etc...



thats my story and i'm sticking to it...


I was wondering if anyone was gonna mention this............

Good post.

[SHNIPE]

You DON'T want to break that out on the trail unless you know what you're doing and know how to fix it... In theory changing a shaft out is relatively easy, but it can take hours and hours depending on how bad the break was, if any of the peices are jamed up in the carrier, what tools and spares you have etc...

If you're just blasting around the desert with no lockers you're prob gonna be fine; but if you're doing any kind of rock crawling, you're likely asking for a miserable experience (not only for you but also for whoever is with you).

thats my story and i'm sticking to it...

According to the pictures you guys seem to have had one hell of a time laughin and joking for the 3 hours it took us ot take apart Davids d35. Or was it just cause someone wanted to kick glen in the DING DING

D44, F9", 8.8, toyota axle are all good options.

Toyotas are pieces of crap. Dont get one of those!!

[GRUNT]

I got the super 35 kit because I was not patient enough to wait for a Cherokee 44 or the like. I don't want to go full width so my options were limited. I wish I would have waited for a 44, they are easy to find on Craigslist, etc.... 8.8 are good to or you can find 9" too. Just be patient. My buddy has been running 35s locked front/rear and hasn't tanked an axle yet. Don't get crazy and you will be fine until you find your 44. I want to go bigger than 33s now, I didn't think I would before. Now I got gears, ARB and discs on a D35. This will last me but I don't dare go bigger until I replace it... JUST WAIT, and do what you really want to the first time my friend... Or...!!!!! I can sell you a D35, w/ super kit, ARB, 4.56 and all new seals... :D

[RokNRich]

DING DING DING....we have a winner.....


Its NOT a simple process, and real quick....it can be a nightmare depending on where/when it happens too.

Another great post !

[sunroom2004]

I can sell you a D35, w/ super kit, ARB, 4.56 and all new seals... :D

I haven't had any issues with my Super35...but then again I've only had it for 6 months.:rolleyes:

My super35 has a Detroit, so maybe I could sell you mine cheaper than the ARB model...:D

[sms1688]

You DON'T want to break that out on the trail unless you know what you're doing and know how to fix it... In theory changing a shaft out is relatively easy, but it can take hours and hours depending on how bad the break was, if any of the peices are jamed up in the carrier, what tools and spares you have etc...

If you're just blasting around the desert with no lockers you're prob gonna be fine; but if you're doing any kind of rock crawling, you're likely asking for a miserable experience (not only for you but also for whoever is with you).

thats my story and i'm sticking to it...

Why you got to make fun of me. :(:D Like I said I have spares just in case I dont want to break it. I try to be as light as possible on the skinny pedal until I can afford the 8.8 that I want. Then I will run 35" tires and really get into some fun stuff

[SHNIPE]

my 35 lasted through all of my beatings and is still only half dead with a cracked carrier. Ran RD, URD, LT, UT and predator with it like that and it survived... if only the shafts were that resilient!

[YJunk]

Why you got to make fun of me. :(:D Like I said I have spares just in case I dont want to break it. I try to be as light as possible on the skinny pedal until I can afford the 8.8 that I want. Then I will run 35" tires and really get into some fun stuff



Hey bud... not trying to make fun; just wanted to give my personal opinion that running it till it pops may not be the best solution; at least not for everyone.

I get that everyone drives different, but when you're crawlin rocks there are certain forces that come into play for everyone... Dave snapped his crawlin up the tiniest little climb you could imagine.

Please understand, I absolutely pounded my 35; it had a lock-rite and 32" tires and never let me down, despite some pretty hard wheeling. But I knew going up to 33's or higher was gonna be the end of it...

Breaking one of these out on the trail is a PITA... Know point in going through it if you don't really have too...

[YJunk]

my 35 lasted through all of my beatings and is still only half dead with a cracked carrier. Ran RD, URD, LT, UT and predator with it like that and it survived... if only the shafts were that resilient!

Your 35 spent most of its time with its tires in the air; kind o hard to snap an axle when its starring at the sky...

[sunroom2004]

Yes the speedo gears are still stock, I use my GPS for a speedometer. :D It works out mathematically so I know it is right :)


Hope you don't mind me asking, but I'm a little curious.

Do you have an automatic transmission? or tires smaller than 33?

Because I checked again today and I'm only running 2,750rpm at 70mph with a stick shift, 33", and 4.56 diff.

[sms1688]

Hey bud... not trying to make fun; just wanted to give my personal opinion that running it till it pops may not be the best solution; at least not for everyone.

I get that everyone drives different, but when you're crawlin rocks there are certain forces that come into play for everyone... Dave snapped his crawlin up the tiniest little climb you could imagine.

Please understand, I absolutely pounded my 35; it had a lock-rite and 32" tires and never let me down, despite some pretty hard wheeling. But I knew going up to 33's or higher was gonna be the end of it...

Breaking one of these out on the trail is a PITA... Know point in going through it if you don't really have too...

NO worries man I was jokeing I dont care I know the d35 will break. I still have to go out wheeling until I get a better rearend thats why I carry spares and know how to change out the shafts. Just saying if you are going wheeling with a d35 spend 40 bucks on some used spares so you arent stranded just makes for a long trip.

[Fire Ball]

I'm running a 3 speed with no over drive. The gear ratio in 3rd is 1:1.

Your stick with 5 spd is probably .79:1 depending on what tranny you have. That would account for the difference. Your tires might also be different than mine.

I have a spread sheet that I did all the calculations for the stock tires and checked it with the GPS. It was right on the speedo +- 2 mph.

I calculated the changes with the 4.56 gears, 33's and again checked it with the GPS. It is right on. My speedo indicates 83 mph, at 3100rpm and 60.5mph on the GPS.


This is also using actual tire circumference, not just 33" tire "size"

Are you going by what the speedometer says or are you using a GPS. If you have 4.56 gears on 33's, your speedo is useless unless you regeared it properly. If you are using the stock speedo gears, depending on what gears you started with, this will determine how much speedo arror there is.

[sunroom2004]

That explains it! Thanks!

[Fire Ball]

Sure sounds impressive huh :) YAWN Sorry for the long post, sometimes I even bore myself :eek:

[sunroom2004]

Sure sounds impressive huh :) YAWN Sorry for the long post, sometimes I even bore myself :eek:

Are you an "over-explainer" too? :)

I'm have this problem sometimes...
I can turn a 10 minute presentation into 1 hour at the office...:D

[99AZTJ]

Thanks for the info and jokes! I've decided to try and find a D44. I figure, why overspend right away when I can just be patient. As itchy as I am right now, I'll wait. I want to do this right the first time, and be cost effective at the same time.

Anyone have one available for $100? That's what I have saved so far after bills and kids video games! :o

[Fire Ball]

It is soooo hard to be patient when doing this. Just relax, the parts guys aren't going anywhere :D They will be there to take your money when you are ready.

I threw a couple bucks into my D35 (about $200) just because it could be a year until I get the cash to do it all. I'm working on my lift and tummy tuck for now and building armor parts for people. Maybe I can make enough money to keep my habit alive another week :D

[99AZTJ]

FireBall....do you have any pics of your ride?

[GRUNT]

I figured out my speed with my YJ... Quite simple really.

33s, ax-5, 4cyl, armor, my big arse = SLOW! :D :D :D

[Fire Ball]

FireBall....do you have any pics of your ride?

It's my baby, of course I have pics :D

Here are a couple pics I took just after installing my rocker guards I made. Probably never see it that clean again :D

http://i85.photobucket.com/albums/k57/jetdriver_phx/DSC01244.jpg

http://i85.photobucket.com/albums/k57/jetdriver_phx/DSC01247.jpg

This was Bulldog canyon before thr rocker guards..


http://i85.photobucket.com/albums/k57/jetdriver_phx/DSC01238.jpg

[Gasman]

Thanks for the info and jokes! I've decided to try and find a D44. I figure, why overspend right away when I can just be patient. As itchy as I am right now, I'll wait. I want to do this right the first time, and be cost effective at the same time.

Anyone have one available for $100? That's what I have saved so far after bills and kids video games! :o


Great choice! I wouldn't spend a dime on a 35. Spend that money on an 8.8 or 44. With an 8.8 you get disc brakes but will need to have the brackets welded on, a TJ D44 will be a direct bolt in but with thinner D35 tubes, and an XJ D44 has thicker tubes but needs the brackets like the 8.8. I would lean toward an 8.8 or XJ D44. Strength wise, they are about equal. Extra expense in the bracket kit and welding but the aftermarket brackets are much stouter than stock. The stock brackets have been known to rip off the housing. I'd also go with 4.56 or 4.88 gears so when you go to 35's, you don't have to regear :D

As far as finding one for $100, it's possible but takes some work. Someone recently found an XJ D44 at a pick and pull on half price day and paid $68 for it or something like that. Generally a complete 8.8 or XJ D44 go for $200-400.

[99AZTJ]

Nice pics....
Thanks for the quick breakdown on prices Gasman.....everything I've seen so far avg about $300.

Where are the nearest picknpull around Buckeye?