axle questions, how does 8.25 compare with dana 35, 44 and 60 axles

The early (through 1996) 8.25 has 27-spline axles that are the same size and spline count as a Dana 35. The housing and ring gear are larger and beefier than the Dana 35, but the shafts themselves are a toss-up.

The '97 and newer 8.25 has larger 29-spline shafts that are nearly as strong as the 30-spline Dana 44 shafts. The pinion on the 8.25 is lower than the Dana 44, though, which makes it more prone to drive shaft-induced vibrations. Otherwise, it's approximately equal in strength to a Dana 44.

Which means it isn't close to being equal to a Dana 60.
 
While the 29 spline may be equal in strength to a 44 the downfall would be C-clips to retain the axles.

The axle tubes are also way beefier than a D35 or D44.
 
ya the housing itself is pretty strong.and with the 29spline axles it is a pretty tough unit but the c-clips are a problem.

very interesting sjx40250 i have not heard that before.i think i need one of those rainbows over my head that says the more you know.lol
 
I have a welded 8.25 with 33's and i pretty much give it 5 kinds hell and it doen'st complain much (tires sure do though)
 
sjx40250 said:
I know of a jeep mechanic of 17 years who claims the spider gears are the week link... worse than the d35C
Click to expand...

I remember reading something about someone mentioning that and it seemed to be somewhat unsubstantiated. IIRC for one the mechanic dealt with street driven rigs primarily. ALso if the spiders are a weak link..... that gives you an even better excuse to lock it up :) I was happy with my 29 8.25 and LS then later NoSlip and the only beef I had with it was that big fat lip on the bottom and maybe the fact that it's c-clipped with 4.56 gearing max.
 
Well, I was surprised to hear it from him after all the statements made on this forum! I can not argue with his experience, however. He did work on, primarily, street rigs. Today he does have a clientele that includes off-roaders.

So should I add fuel to the fire? He also stated that he has repaired more 231's than 242's! My suspicion is that most of the 231’s were behind 5 speeds. There are more 231's on the road and trail than 242's.

I am simply relaying his statements and believe he has integrity, IMHO. I have no reason to discount any of the experiences on this forum either, so it comes down to specifications and which have the most value for the application. In the end, we each get to make our own choices with the the information available and the value we put on each one. That statment is not restricted to just to our rigs. It is what makes this country great and unique!
 
Well after owning a 94 Dakota Reg Cab short bed sporting a 5.2 Mag, 46RH auto and 8.25" with 3.55 and limited slip for 8 years I am impressed with it's durablility. Maybe trails are different but there were many times I misbehaved with one foot on the brake and one on the gas. After I added the MP headers, MP computer, M1 2 bbl intake that truck would move out. Heck, it was fun to light them up with a car on a trailer behind it. :dunno:

may guys running 300+ HP and 325fl/lbs of torque thru the 8.25 in the Dakota world without probs. More than 350HP then things get ugly :repair:
 
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Well the 231 repair I can understand because probably he had whole bunch of people drive in 4wd in a 231 equiped on a street. So you really have to look at the whole picture before you make a decision about what some piece of information means.
Btw, what does having a 231 behind a 5 speed have to do with breakage?

sjx40250 said:
Well, I was surprised to hear it from him after all the statements made on this forum! I can not argue with his experience, however. He did work on, primarily, street rigs. Today he does have a clientele that includes off-roaders.
So should I add fuel to the fire? He also stated that he has repaired more 231's than 242's! My suspicion is that most of the 231’s were behind 5 speeds. There are more 231's on the road and trail than 242's.
I am simply relaying his statements and believe he has integrity, IMHO. I have no reason to discount any of the experiences on this forum either, so it comes down to specifications and which have the most value for the application. In the end, we each get to make our own choices with the the information available and the value we put on each one. That statment is not restricted to just to our rigs. It is what makes this country great and unique!
Click to expand...
 
Okie Terry said:
While the 29 spline may be equal in strength to a 44 the downfall would be C-clips to retain the axles.

The axle tubes are also way beefier than a D35 or D44.
Click to expand...

Can you explain to me how method of axle retention has anything to do with axle shaft strength?

CRASH
 
Who says the 29-spline shafts are as or nearly as strong as the D44 shafts? It's tiring to "hear" people repeat what they heard, not what they know. Look for yourself at the shaft diameter of the D35, 27 and 29-spline 8.25, and the D44. The size of the 29-spline is closer in size to the D35 than it is to the D44. Perhaps then we should be saying it's "as strong as the D35" instead of the D44. :confused:

Tom
 
8.25" Ring Gear = 8.25"
D44 Ring Gear = 8.5" (+3%)
D35 Ring Gear = 7.5" (-9%)

8.25" Axle Shaft Dia. = 1.21"
D44 Axle Shaft Dia. = 1.31" (+8%)
D35 Axle Shaft Dia. = 1.16" (-4%)

8.25 Axle Spline Count = 29
D44 Axle Spline Count = 30 (+3%)
D35 Axle Spline Count = 27 (-6%)

8.25 Axle Tube Dia. = 3"
D44 Axle Tube Dia. = 2.76-2.72" (-8-9%)
D35 Axle Tube Dia. = 2.64-2.48" (-12-17%)

EDIT: Percentages are rounded off. No figures yet for Axle Tube Thickness, nor any numbers concerning pinion strength.
 
Let's try some actual stats:

The 29 spline 8.25 axles are 1.21" diameter. 30 spline D44 axles are 1.30 diameter. You can find axle shaft strength ratings on Moser's site (at least last time I checked). An alloy 8.25 axle would be close in strength to a stock 44. Alloys make excellent sense for an 8.25. Keep your stock shafts as spares.

The 3" diameter 8.25 housing appears not to suffer the housing flex that plagues D35's, and hence we don't hear much about busting 8.25 shafts, especially not the 29 spline.

The 8.25 pinion is 1.675" with 27 splines, compared to something like 1.35" for the D44 (and 23 spline???)...much beefier. The 8.25 R&P should be comparable in strength to the D44.

The 44 is a better axle than the 8.25 in every way, IMO, but there is no reason to get rid of an 8.25 for 33" tires unless you have constant gear noise problems like I did. The axle shafts are identical side to side, which is nice for spare parts, and disc brakes take away some of the c-clip retention concerns.

Just get a full carrier replacement diff, and you'll have removed what I have also heard is the major weak link in the 8.25 (carrier/spider gears).

Nay
 
You have to take in account the housing. That is the D35's weakest point, not the shafts. My locked D35 held up pretty well with my 33's. So therefore even though the 29 spline shafts are smaller, it's the tubes and the housing that push it closer to the D44 level of strength.

FWIW, 8.25's like D35's are worthless unless you get them rather cheap. ;)
 
tjl1388 said:
anybody have any pics of a welded 8.25, what does that strengthen, and is there any way to convert to the 29 splines?
Click to expand...
they weld the spider gears together to lock the rear axles together...
the best conversion to 29 spline is to buy a no-slip for a 29 spline and buy two 29 spline axles...or three and have a spare ....
 
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