I ran 33's with an open diff before sliding my 8.25 under my XJ. I was always aware that it was back there and used the skinny pedal with caution. I snapped a 35 on my 99 TJ with 31's & an open diff.

Look at most TJ guys and they're running 35's on their D35. Just gotta wheel smart & carry spare axles & tools to do trail repairs...

 

I guess sometimes things happen but there are also stories of people breaking Dana 44s. I'm not saying d35s are the best thing out there, I'm just saying I don't see anything wrong with them

 

There's nothing wrong with a D35. It's just small. Fine for street or light trails but too small for serious offroad. Once you start talking to the hardcore people they'll say the same thing about a D44. Then if you put a D60 in the rear almost certainly someone will say a 14B or Rockwell is need. It's all just relative.

 

One of my first four wheeling trips I ever went on a friend broke his dana 35. When I got my cherokee, it had a dana 35 and all I did was worry about it breaking the entire trip whenever I took it out. So I swapped in a ford 8.8 so I can eventually go up to 35s and just have the piece of mind about it not breaking. When I eventually really start to beat on the it I am sure I could/will break the ford 8.8 but at least I don't constantly worry out it when I am supposed to be having fun. Just my thoughts on it. Plus now having rear disc brakes is super convenient!

 

I was in the same boat but was visiting offroad forums for about a year before I bought my rig with D35. Just like you I did nothing but worry the whole time during offroad trips until I put in the C8.25. Then I stressed over the super weak front U-joints and finally broke one. After upgrading that we saw a guy that had broken a knuckle. Now that's my current worry.