mudderx

I have a dilemma coming up in the next few months and could use some help from you guys.
I want to get a rear locker for: a) 27 spline C8.25 and upgrade axles or b) 27 spline D35 and upgrade axles or c) deal with setting up an LSD 8.8 and buying a super 88 kit (longer, stronger axles and C clip eliminator).

I’m currently running a non-ABS Chrysler 8.25 from a 94 Sport (Open diff? w/27 spline?) Is there any way to tell the year without counting splines? Or I have my stock ABS Dana 35 in my shed still but the D35 is missing 2 spider gears (locker will replace them) but I don’t know how to tell if my D35 is an open or limited slip differential. *Pictures below* Locker Manufacturer says diff must be open. Why?

Choice #1 IF my D35 is open and IF I put a locker (Aussie or Powertrax) in it with Superior Axles will it be comparable to 30 or 31 spline axle from an 8.8 or D44?

Choice #2 IF my C8.25 is open and IF I put a locker (Aussie or Powertrax) in it with Superior Axles will it be comparable to a 30 or 31 spline axle from an 8.8 or D44?

Choice #3 Do the 8.8 swap and buy a super 88 kit (most expensive route and most work).

SeriousOffroad

First off, I would not recommend spending any money on upgrading a d35. It simply isn't worth the time or money.

If your 8.25" is 95 or older then there's no reason to count the splines. It is a 27 spline axle. mid 96 was the change-over year and you'll still have to count the splines. 97+...all 29 spline.

A 29 spline 8.25" axle shaft is .1" smaller in diameter than a D44, has 1 less spline, and is slightly weaker than a D44 shaft. It is not as strong as a Ford 8.8" but then again the 8.8" has a massive diff that will dig ditches if you're running anything smaller than a 35" tire. Adding alloy shafts will definitely bump up the strength.

The Ford 8.8" axle is a strong but it does have it's drawbacks as well.
As mentioned, the diff is massive and suitable for "small" tires.
The diff is offset and this is a drawback for some folks.
The tubes must be welded where they enter the diff since they have a tendency to spin in the housing. this is a major flaw in the design as far as offroading is concerned. Don't skip this step!
The carriers are not the strongest in the world. Do a google image search for Ford 8.8" Carnage. Ditch the carrier and get a fullcase locker instead....it really is money well spent.

Adding a set of alloy shafts and a c-clip eliminator kit makes the 8.8" wider so that it is just about the same width as a stock XJ rear axle.

FWIW, (My $.02)
Building an 8.25" is the way to go if you are going to run 35's or smaller.
It's a direct bolt in and easy to find.

A d44 is preferrable simply because of the huge amount of aftermarket support and lower build-up costs.

Ford 8.8" is certainly do-able but should it's the 3rd option if 1 and 2 can't be done.

HTH

xjmarc

Like he said, skip the 35. If you plan on running a 35 or smaller get a locker for the 8.25 and call it done. I'd find an extra shaft or two, they are the same length on both sides unlike most, so if you do break one. If you want alloy shafts get 29 spline since they will work in your 27 spline housing and get the approprate locker. The reason lunchbox lockers need open carriers instead of LSD carriers is because of the room they take up. I personally am not a fan of the 8.8 and for what it cost to build one with c-clip elimators and such you can have a much stronger and cheaper 9 inch or D44 that never had c-clips and way more aftermarket support.

mudderx

Funny thats the responce I expected for the d35. I am not sure of the year on the c8.25 I only know I took it out of a lifted 94, I was hoping there was an easy way to tell the years apart. Will 29 spline axles fit in my 27 spline diff once I put a locker in or does the whole carrier have to be changed out?

SeriousOffroad

You'll need a new carrier and side/spider gears.

If you are going to build the 8.25" with new shafts and a full case locker then keep the one you have and just swap the guts.

If you want an open carrier for a lunchbox locker and plan on running stock gears and shafts, ditch the current axle and grab a 97 + from your favorite JY.

Make sense?

JeepinXJ01

a super 35 conversion will hold up to 35" tires no problem and if you upgrad thats to lets say chrom ollys then it will definatly be fine!

SeriousOffroad

Not without trussing the housing.
D35 shafts tend to snap as a result of the housing flexing. Once they do the axle snap right at the splines.

Alloy shafts and a truss....you're spending more than an an axle swap.

TheJerm

I simple threw a lunchbox into my 27 spline 8.25 and beat on it with 33's and 35's with no problems. Well one issue I have now is the springs in the locker are worn out after ~40-50K miles

xjmarc

Guessing you got a lockright. Had that problem with my Yota and it would unload on side hills. You can get new springs but they'll wear too. Just a problem with lockrights. Had an Aussie in my old axles for several years and my buddy is still running them 2 years later without any issues.

xjmarc

As long as you stay on pavement. I ran alloys in mine with 33s and broke 4 shafts before they gave me my money back. Like stated the housing flexes and then bends and the ring gear is rather small and weak as well.