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Unread 11-21-2008, 03:14 PM   #1
Mr_Clickerson
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Chrysler 8.25 vs Dana 35?

I just found out, after thinking I had a Dana 35 in my rear end, that I have a Chrysler 8.25... I was a bit suspicious when I noticed the rear axle tubes looked much larger than the front, which I was almost certain was a Dana 35...

What I want to know, is how much better, if at all, are the Chrysler 8.25 over the D35? I ask because I've heard of people swapping them in over a D35.

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Unread 11-21-2008, 03:15 PM   #2
dagen
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from what i remember the axle tubes are slightly thicker.

seems to be the consensus that the 8.25 is stronger. not by a lot, but enough.
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Unread 11-21-2008, 03:16 PM   #3
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The 8.25 is better than the Dana 35. Not as good as the Dana 44. IMHO
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Unread 11-21-2008, 03:19 PM   #4
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If you have the origional 94 model 8.25 it is 27 splined, and a bit stronger than the dana 35. But the 97 and up 8.25 is 29 splined axles, and compareable to the dana44.
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Unread 11-21-2008, 03:19 PM   #5
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since im assuming u have the pre 97 xj that u have the 8.25 with the 27 spline shafts which basically isnt much stronger the the d35... u could always just swap in some larger spline shafts. just got to a upull yard nd see if u can find a 97+ xj with the 8.25 cus those came with 29 spline shafts which can easily handle 33s locked even 35s with some chromo shafts might as well just grab the whole axle nd just swap it
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Unread 11-21-2008, 03:21 PM   #6
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The 8.25 you have is only marginally stronger than the Dana 35. Your 8.25 still has 27 spline shafts. The 8.25 from 97+ Cherokees have 29 spine shafts, and are substantially stronger. You should be able to buy a locker for the 29spline 8.25 and 29spline shafts and put them into your carrier. Some say you have to change the carrier over as well. I have never personally tried this, so I do not know.

The other advantages of your 8.25 over the D35 is the stregnth of the housing, gears, tubes, and carrier. All of the aforementioned are bigger and stronger than the D35.

Your front axle, if stock, is a Dana 30.
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Unread 11-21-2008, 03:24 PM   #7
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Thanks a lot guys! Quite a wealth of information.
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Originally Posted by Lamb of God
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Unread 11-21-2008, 03:33 PM   #8
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Quote:
Originally Posted by xjfever View Post
If you have the origional 94 model 8.25 it is 27 splined, and a bit stronger than the dana 35. But the 97 and up 8.25 is 29 splined axles, and compareable to the dana44.
Many, MANY 96's came with 29 spline 8.25's. I have only ever seen ONE 27 splined 96. I think early build date 96's came with maybe a few 27's. We need to put this myth to bed.
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Unread 11-21-2008, 03:34 PM   #9
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Quote:
Originally Posted by xGArfx View Post
since im assuming u have the pre 97 xj that u have the 8.25 with the 27 spline shafts which basically isnt much stronger the the d35... u could always just swap in some larger spline shafts. just got to a upull yard nd see if u can find a 97+ xj with the 8.25 cus those came with 29 spline shafts which can easily handle 33s locked even 35s with some chromo shafts might as well just grab the whole axle nd just swap it
XJ axles are semi float unless you do the hub conversion on the front, but either way use 1541h shafts in the rear, not chromoly... or they will snap
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Unread 11-21-2008, 03:36 PM   #10
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Originally Posted by 4.0H.O.XJ View Post
Many, MANY 96's came with 29 spline 8.25's. I have only ever seen ONE 27 splined 96. I think early build date 96's came with maybe a few 27's. We need to put this myth to bed.

You know I have heard this, I've got my 8.25 from my 96 sitting in the shop. I need to get off my lazy ____ and check the spline count.
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Unread 11-21-2008, 03:44 PM   #11
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i just saw a jeep with a D35 in the back... that thing looks tiny next to a C8.25... I did not think there was that much of a differance but the tubes half to be at leas 1" smaller on the D35 then the C8.25
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Unread 11-21-2008, 06:59 PM   #12
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dana 35 tube is 2 3/4in c 8.25 is 3in tube diameter
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Unread 11-21-2008, 07:08 PM   #13
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Quote:
Originally Posted by 4.0H.O.XJ View Post
Many, MANY 96's came with 29 spline 8.25's. I have only ever seen ONE 27 splined 96. I think early build date 96's came with maybe a few 27's. We need to put this myth to bed.
What myth? I'll reiterate this again here...every 96 ive seen and have had the opportunity of knowing about, has had 27 splines.
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Unread 11-21-2008, 07:20 PM   #14
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Everyone else has basically summed it up. The pre '97 8.25's are only 27 spline and are comparable to the the Dana 35. The '97 and later 8.25's are stronger and thus more desireable than Dana 35.

However, the Dana 35 will be good up to a 31" or 32" tire. After that you need to start thinking of upgrades.
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Unread 11-21-2008, 07:24 PM   #15
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The only 96's with 29 spline shafts are the LATE model build units. The one I know about was a November built one.

The 27spline 8.25 is a stronger axle than the D35.

The ring gear is 8.25 verses the D35 7.62.
The 8.25 pinion is the same dia as the D60.
The 8.25 axle tubes are thicker and stronger than the D35.

It's not as strong as the 97+ 8.25, but IMO it's stronger than the D35. One of the biggest down sides to the D35 is the axle tube flex. That flex puts stress on the internals as well as the shafts. Any time someone asks about a Super35 kit, I recommend they truss the axle as well.
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