Regearing a Dana 35?

[nwcherokee]

I have never messed with axles before, other than changing the diff. fluid. A friend of mine just toasted his rearend (simply by backing out of a parking space) and so we are looking at fixing it ourselves, but neither of us have any experience with this. He is hoping to take advantage of the situation by putting in taller gears. I know that the front has to be done as well. I'm assuming it's a Ring & Pinion that is gone in the rear, but i'm not positive as we haven't cracked it open yet to see. I've done some basic work, alternator, water pumps, head gaskets, brakes, lifts, etc. Is this a job that could be tackled by 2 novices or better left taking it to a shop? Any special tools needed & how hard a job is it really?
Thanks

 

[mini=man]

If he needs a vehicle soon, take it to a shop. A shop can have it done withing a day if they are out of the vehicle and given they are slow. But if you're up to the challenge (and it is a challenge) you can give it a try. When I did mine it took a little more than a week each axle because I had work still too. There are special tools like dial indicators, calipers, inch/lb non clicky wrench, foot/lb torque wrench that are needed to make this go at all. But if he's already blown it up on the street he should prpbably upgrade. Go to a local pick and pull and grab a 8.25 out of a 97+ XJ with a 4cyl and you'll have a much stronger axle and factory 4.10 ratio.

 

[kastein]

x2 on finding an 97+ 29 spline 8.25 with 4.10s, if you can't find one that already has them, find one anyways and regear it instead. 100 dollars and will keep you from blowing up that 150+ dollar gearset you're about to buy...

The first rule of jeep club is NOT to pour money into a d35. The second rule of jeep club is if you already have poured money into a d35, stop doing so.

 

[nwcherokee]

I guess I didn't post his rig because I didn't want to get :flame: for posting about other vehicles on a Cherokee forum.

It's a '97 TJ 2.5 4 cyl. on 31's. The stock gearing is 4.11. I think we've already decided that he is just going to find a stock D35 with 4.11's & swap the whole axle. I've already found one on Craigslist for $250. It sucks for him because his job is being terminated Dec. 1st, he's selling his house because of the job loss and now he has to bring $16k to the table at signing and he's still in the middle of an adoption also. Needless to say he's broke. On top of all that, we were supposed to be going wheeling next weekend. Thats off now.

 

[kastein]

oh, that really sucks... hmmmmm.

FYI, I'd be fine helping with a TJ as well as long as he realizes XJs are better :roflmao: (yes, I'm mostly joking, personal opinion)

If he can afford it (~400-500 total parts cost including many new) I would do an 8.8 swap. If not, toss in another stock axle... but see if you can find one cheaper, at least around here a rearend is 130 dollars in the you-pull-it yard.

 

[nwcherokee]

I've found an exact match D35 with 4.11 gears to rotate into his TJ, for $250. I offered the guy $175 for it. We'll see what he says.
Some good news is, in searching for his axle, I found a '97 Chrysler 8.25" that is only minutes away, that will fit & replace my 35 on my XJ, for $175 & it's already been pulled

 

[IslanderOffRoad]

The D35 is considered slightly more acceptable in TJ's just because so many run it... and there aren't as many easy bolt in swap options.

I'd grab that rear for the price, especially if time is a factor, you could have it swapped in an hour or two. Then start looking for a 44 to replace it.

Remember, his front gears now don't match so DO NOT put the Jeep in 4wd for any reason until he does so.