The dana 35 works fine up to 31 tires and stock gears, when you go to 33s and 4.10s you experience failure.

Just so you know you have the newer 8.25 with the bigger spline count and many tests I have read say its just as strong as a d44. Even the max tier guide I got from aurbon gear says they are rated for the same max tier size. And with your axle you can get a disk brake set up for it out of a liberty that's a bolt on!

*almost* as strong as a d44. D44's have one more spline count, and they aren't c-clipped like the 8.25.

a D35 is not as weak as some people say but, I had an MJ with the D35 and did a dukes of hazard impression one time and ended up pulling the axle tubes out of the pumpkin, spinning the diff, and breaking the rear u-joint. I used a come-along to pull the tubes back in and a pipe wrench to realign the housing, then welded the tubes in place and made an axle truss for it. I never had a problem after that.

That is the MOST EPIC DANA 35 FAIL IN HISTORY! Pics????

no, no pics. that happened about 6 years ago. I no longer own my MJ.

I had been thinking of doing the same thing

rockcrusher and kryptonite come to mind for the 8.25

damn....you got me all excited.....talk abut a buzz kill. lol

Does anybody know the dimensions on the D35? ie tube diameter, thickness, overall length??

Tube dia. I wanna say 2.75" , WMS-WMS is 60.5"

I laugh at anybody wanting to put ANY money into a dana 35. There is enough info on the internet that you would be an idiot to truss/gear/polish etc etc The crappy D35.

The only thing i would do for a d35, is maintain it if i were DD with it.

x2

that axle is a c 8.25... It is stronger than the d35. If your jeep is just a DD and you do some wheeling every once in a while then the 8.25 is plenty enough for what you are doing. Especially since your just runnings 30s

is there any scientific proof this it true? naive comment. I have seen d35's twist tubes and break ring gears on 30 and 31 with stock gear.