Originally Posted by exc911ence
I used to have a 91 XJ Laredo with the 4.0L HO engine and 5-speed tranny. I thought the rear axle was a Dana 35... am I wrong? Why I ask is that the guys on the TJ forum are always trashing the Dana 35 as being a weakling but if that's the axle I ran in the XJ, it took TONS of on and off-road abuse (including a trip to the dragstrip where I showed it no mercy) and never blew-up. So what's the deal? A Dana 35 in a 4-cylinder TJ will die the second it's off-roaded yet it withstands 190hp and power-shifting in a Cherokee?
The D35 is a relatively weak axle, but you have to look at what you are comparing it to. There are a lot of TJs running 33s. The D35 isn't quite strong enough to handle a 33in tire when wheeling it hard, but it is plenty strong enough to handle stock sized tires.
The c-clips in the D35 are weak points as are the axle tubes in general. They are known to bend and crack -- which is why axle trusses are sometimes used.