Superhero

When I got my XJ I thought it had a D35 in the back so I have been planning my build around finding a D44 or Ford 8.8 to swap in. Well, I just read somewhere that most '92 XJs have the c8.25 so I figured I'd run outside and double check. Sure enough that's what I've got. Needless to say I am super stoked, to the point I want to triple check it just to be sure.

Anyway, this should be more than enough to run 31s or 32s and do some minor towing without fear of trashing it or an axle yes? It's got 172k on it so a rebuild is in its future. Can anyone recommend a good rebuild kit?

While on the subject of differentials, what kind of wheeling would cause someone to start considering going with a beefier front diff?

Thanks!

jeepkid46

I got a chrysler with 31s and wheel pretty hard i would throw some bigger spline axles in from a newer jeep 29 spline maybe an lsd would be good i would not worry at all with that small of tire i have towed twin three passenger jetskis a 22 ft wakeboard boat my 4 wheeler and my duck boat loaded with duck gear

Superhero

That's good to hear.

When I go to rebuild it can I buy a kit that uses stronger, better parts?

1904-96xj

No kits are available, but companies like Superior, Yukon and USA Alloy all make axle upgrades for the 8.25. One thing to remember when changing from 27 spline to 29 spline is you have to replace the diff carrier and gears as well. This usually requires a driveline shop installation due to ring and pinion adjustment. So, you're lookin at almost or over a thousand bucks to swap if you include a locker. The nice thing about 8.25 is the axles are the same size so you only have to carry one spare at minimum.

jeepkid46

You could get heavy duty yea like carrier but would require shims for gears

SeriousOffroad

What are you planning on "rebuilding"?

N20jeep

FYI the 27 spline shafts in the 8.25 are actually smaller than the d35 shafts

winston427

You do not have to replace the gears, but you will need to have it set back up properly when changing the carrier. The cost of the labor will grossly outway the cost of simply picking up a 29 spline 8.25 at the junkyard. You can then install an Aussie locker for around $350 and be on the trails having a blast.

Correct, the only strength advantage the 27 spline 8.25 has over a D35 is the axle tubes. They are larger and have a thicker wall construction than the D35.

Rock Toy

Yes, the 27 spline Chrysler 8.25 has a 1.17 diameter shaft while the Dana 35 has a 1.18 diameter shaft. The minor shaft diameters are 1.11 on both shafts though. The pinion and the axle tubes are both larger on the 27 spline Chrysler 8.25 than on the Dana 35, and using stock 29 spline axles in the Chrysler 8.25 will increase the strength by about 25 per cent over the 27 spline shafts. So the Chrysler axle even with the 27 spline shafts is stronger and less expensive to upgrade than the Dana 35.

Superhero

Replace the bearings and any worn gears.

Superhero

Hmm I have a '92 so I have a 27 spline rear. Is a 29 spline rear a bolt-in upgrade?

Thanks for the replies and input everyone!

jeepkid46

Yes it is

Superhero

Perfect! Thanks.

SeriousOffroad

Do you know to set up gears?

The reason I ask is that the 8.25 uses adjusters and not shims for the carrier bearings. It's not simply a matter of yanking out the old bearings and installing new ones.

Superhero

Oh. I didn't know that. Nope, no idea how to set up gears. I'm guessing this is something I'd need a shop for?

Would I be able to put 29 spline axles and an Ox or ARB locker into my 27 spline 8.25 in my garage or would this require a shop and specialized tools/knowledge?