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Depends on what your stock axles are? Front is probably the Dana 30, ther rear might be a Dana 44, but is probably the Dana 35.
You will find some strong opinions on this one. Here's mine ![]()
First, what kind of use? "Hard-core" rock crawling, waterfall climbing, jumping, pedal to the floor, dhange your underwear or moderate trails, hills, rocks, and general fun?
The Dana 35 is useable up to a true 33 inch diameter tire if you are not involved in extreme off road challenges. Moderate trails, hills, rocks, mud, etc. are fine with 33 inch. I would recommend upgrading however (cheaper than a new axle, less trouble than a junk yard) and installing either a Superior Super 35 kit with ARB locker (I like the ARB's best) or a Warn full floating axle kit.
Oh, put a truss on any Dana 35 or 44 you install. In fact, I recommend a good tensile type truss on the bottom of any differential which sees trail use.
If you are committed to run 35's there are a couple of options:
Keep the Dana 35 but you have to upgrade with a Warn full float or Superior Super 35 upgrade. Either of these takes you basically to a Dana 44 capability. If you are into moderate trails, you shouldn't have a problem. You should be fine even on more challenging stuff as long as you aren't abusive.
Next option, a Dana 44 or Ford 8.8 inch. These are pretty equivalent and you can fuss and bother trying to make a junkyard find work or just bit the bullet and buy one pre-made you just bolt in. These are OK with 35's but you are reaching the limit. There are also after market high strength axle shafts and kits you can install.
Next, a Dana 60 or Ford 9 inch. These are better suited for 35's and some use bigger tires on them. You can as above, scratch the junkyard for a close fit and break our the arc welder or there are several sources for high strength Dana 60's and Ford 9 inch axles. These are what you should look for if you want the "hard-core" experience and want to really push youself and your jeep. Plan on spending some serious $$$ however.
An up and coming axle is the Rockwell 2 1/2 ton. between a 6:1 and 7:1 final ratio, can take pretty much anything you dish out, weighs a lot, I think in the range of 600 to 700 pounds. These are definitely a fabricators choice. Plan on a lot of custom work and I think you only get two choices for a carrier, open or detroit locker.
You really need to decide what you do with the jeep, being honest with yourself and then weigh what you are going to do against your ability as a fabricator or your wallet.
Next, you need to have fun and get some mud on that jeep!
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