cmarr6

I have two jeeps, one and 85 pioneer that I swapped in a SBC 350/350TH combo and the other a 91 limited with 4.0 HO AW4. Both jeeps have about 3" of lift and 31" tires. The problem is, The 85 has 4.10 gears and is geared too high, the 91 has 3.55 and is geared too low. Both have the Dana 30/35 combo axles. Can I just swap axles and solve two problems at once? Or would swapping just the gears be an easier alternative? I have done a fair amount of research and don't forsee any problems, should be a straight swap, but I want expert opinions from you guys if this will work or is there something I am overlooking or haven't forseen.

OttawaXJ

Swap the whole axles, swaping gears would mean rebuilding them basically and a d35 behind a SBC is an accident waiting to happen so no sense in spending more money on that axle. Wait till it explodes and toss an 8.25 in it if you're keeping the jeep at that ride height. if you're going bigger then you'll want an 8.8 when the d35 goes.

cmarr6

Good point about the D35 behind the 350. I have been babying it trying to make it last. I don't do any serious offroad stuff, just a winter/snow vehicle mainly, no good wheeling around here. I have done some pretty good burnouts with it and it hasn't failed yet. Not planning on going bigger but you never know. But is this a direct swap on both the front and back, nothing i haven't overlooked? U-joints the same size? Control arms the same? etc.

Stroked99

Yes, everything is just unbolt, swap, rebolt. Way easier than swapping gears. And if you are just using it for a winter vehicle, then when the d35 explodes, just use an 8.25, its plenty strong for you. No need to do all the work to make an 8.8 fit.

karl4x4

I have to agree with all the above.
Don't spend any time and money on D35.

Wait for it to break than go to 8.8 with disks. its one of the best mods I did. (after going true 4 D35)

Maybe just put bigger tires on one and smaller on the other. Its hell of a lot less work.
with 4.11 you could go to 32, 33 ish and rpm would be happy.
with 3.55, 30" tall max to keep rpm happy

cmarr6

I would like to go with bigger tires on the 85, that would solve that problem, but I don't want to go any smaller with the 91. It is the wife's DD and she is not happy with the way it drives after the lift and bigger tires. The mileage took a dive and it has a little DW. I did a driveway alignment and a new trackbar bushing and took care of most of the DW. Still have moments when it feels like it is going to start, then fades away. Getting an adjustable track bar when I can afford it. One thing I told her is just drive it in 3rd gear, not OD. Its the AW 4. She only drives about 15 miles each way to work and back, would this cause any problems with the tranny? It brings the rpm's back up to about the original driving range so I think it would improve the mileage back to original, but I'm afraid it would do some harm to the tanny.

Stroked99

It's fine to drive in 3.

karl4x4

DW sure is a *****. I had to do some pretty extensive steering mod to stop it. At the end I still had a little and a new steering damper ended it. Also, it was worse with stock tires than 34s. Figures. Nothing wrong with not using od if not need it. If you are worried about the transmission switch to synthetic fluids. Try AMSOIL.com. By a couple extra litre for your transfer case. You'll notice an improvement. I've sold the stuff for over 20 years and never had a customer that didn't notice an improvement in transmission shifting. Low and high mileage vehicles.

Back to original question, I would probably switch diffs and baby the one but look for 8.8 anyway. They pop up all the time. I lucked out with mine under$300 31splines and diss. Other than wheel bearings, it took some very serious abuse that would have snapped D35 multiple times over. The 4.7L can dish it out real good.

Stroked99

Under $300 is good for you? I got mine complete with brakes and lines for $150 and i can probably count 20 at a time in the junkyard.

cmarr6

What makes and models should I look for with an 8.8 that will work?

Parsnip

65$ for my buddies haha

Stroked99

1995-2001 ford explorer will have disk brakes and 31 spline axle shafts.

cmarr6

Wow, just read the thread about the D44 that turned out to be an 8.8. Don't think I'm ready for that much work. A 8.25 would be a better option for me it think, that's pretty much a straight swap isn't it?

karl4x4

Just for the disk brakes it's worth it to me.

OttawaXJ

Discs swap right onto a c8.25 with out any hassle really. Just need a small die grinder to round out a couple spots on the dust shield and away you go.

8.25 is easier for most people as it requires no welding or special fab skills. Plus the 8.25 housing isn't as big so its not a rock magnet. if hes not going above 35s theres no reason to go above a 8.25