d35 to chy8.25 swap (DS length)
 

If I swapped these axles, would the DS need to be longer or shorter? Significant difference?

I "Think?" it will just bolt right in but I may be wrong. I'm sure someone will chime in soon to give you a definite yes or no...Tj

the driveshaft needs to be shorter. the yoke on the 8.25 and d44 is longer than the d35. just pull a driveshaft from a junk yard car that has the same transmission/t-case set up as yours but with the 8.25 rear end.

I was afraid it would need to be a bit shorter, bummer. I'm 2wd, so I'm not sure I can find a 2wd/ax15/c8.25 combo out there!

Depends, if your lifted then the original drive shaft will be fine. I swapped in the 8.25 and kept my drive shaft, but I am sitting on 4.5in lift.

i just swaped from a d35 to a d44 an no issues in lenght....just needed new u bolts....should be same for u

it may be different for you because of the fact you don't have a transfer case, so your current driveshaft may have enough play in it to work for the 8.25, and if you are lifted, or planning on installing a lift, that will definitely help compensate.

Thanks for all the input. I had some time Sunday to check it out a little more and get some pictures as well. I'm sitting on 3.5" of lift so I unbolted the end to see how much extra space I might have. The first one is the DS at the transmission as it is now while bolted up.

http://i592.photobucket.com/albums/t...J/DSC_0013.jpg

Then with it unbolted and pushed in.

http://i592.photobucket.com/albums/t...J/DSC_0015.jpg

And at the other end.

http://i592.photobucket.com/albums/t...J/DSC_0017.jpg

I've got about an 1-1.5" to work with. You think the 8.25 will give me any trouble?

Nope, you should be good.

I just did a d35 to chry 8.25, it actually pushed my rear DS back into the Transfer a lil more than it was on the D35. I will be a direct swap. Only thing you will have to worrie about while doing this swap is ur e-break, i just cut mine off since i was putting a 00 8.25 into a 90 the e break mounts differently. That will be your only issue.

edit: the 8.25 pinion sticks out farther than the d 35 as well, its only a inch or 2 but u can see a difference.

what you will have to worry about is when your drive shaft is parallel with the tranny the whole system will be at its shortest length. if you have the drive shaft butted up at the end of the tranny when your suspension cycles it will push the drive shaft into the tranny more resulting in some serious damage.

I was just thinking about that very thing and started getting concerned and then saw what you wrote. I talked myself out of thinking the driveshaft did not slide in and out of the tail cone when the rear suspension was compressed because the axle does not move horizontally. Then I started doing a little mental geometry and realized you are definitely right, the DS will compress into the cone when the rear is loaded. The question would be how much free space would it need to operate safely.

Thanks for your input! As was mentioned in the previous two posts, do you feel you have sufficient room for the DS to travel when loaded? Perhaps a picture of your DS entering the tail cone? Thanks to everyone for helping me think through this!

I will have some pics tonight once i get home from work. how it will help you out.