D35 took a crap! Repair carrier/spider gears or upgrade to D44? - JeepForum.com
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Unread 05-22-2012, 11:30 AM   #1
HootenTJ
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D35 took a crap! Repair carrier/spider gears or upgrade to D44?

D35 spider gears shredded, broken carrier, and possibly need new ring and pinion. I have the 2.5L engine and one day would like to put in a I6 but that's not happening for a couple years. If I put in a super 35 kit would the 4.0 handle it or would I be setting myself up for a breakdown? Also if I decide to do the work myself would a basic home garage be able to do it or am I looking at special tools and equipment needed to swap carrier/spider gears? I've swaped my 2.5L engine before but have never tackled any axle work. Thanks for all feedback.

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Unread 05-22-2012, 12:14 PM   #2
Knuckelhead
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Have you looked for another d35 for cheap?...
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Unread 05-22-2012, 12:23 PM   #3
FarmerinVA
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Quote:
Originally Posted by HootenTJ View Post
D35 ... possibly need new ring and pinion
That's a big variable because it adds so much to the price and the time-out-of-service.

IMHO, new R&P is the clincher. Cost-wise, it's hard to justify the Super 35 kit if you are doing a new R&P at the same time. The Super 35 kit makes more sense if you are building in stages.

Plus there is the question of why you broke the D35 carrier. If it isn't a total fluke, the Jeep gods are telling you that you need a stronger pumpkin, not a second chance for the D35.
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Unread 05-22-2012, 12:40 PM   #4
hallsofstone
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Ford 8.8 should not be ruled out of this decision. Tons of discussion on this topic (D44, S35, 8.8) if you use the search function. TJ D44's are not exactly easy to find.

In any event, this may be a good opportunity for you to regear.
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Unread 05-22-2012, 01:05 PM   #5
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Consider this: most experienced folks here think putting an I6 in an SE is too hard compared to going all the way to a V8. So I would opt for the strongest axles you can afford.
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Unread 05-22-2012, 01:16 PM   #6
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8.8 or Dana 44.
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Unread 05-22-2012, 01:17 PM   #7
cfmiller58
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i went for the d44 when my pinion bearing went and only because it just happened to be available and came with a matching front end. if i had the time to do it id go 8.8
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Unread 05-22-2012, 01:18 PM   #8
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Originally Posted by tdavid14 View Post
Consider this: most experienced folks here think putting an I6 in an SE is too hard compared to going all the way to a V8. So I would opt for the strongest axles you can afford.
What? I don't think that "too hard" is the case. More like "might as well go big since I have it apart anyway" is more like it. All the same, plenty of people drop in 4.0's after their 2.5's crap out.
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Unread 05-22-2012, 01:48 PM   #9
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Can I assume if I decide to go with a Ford 8.8 I would need someone to weld on jeep TJ brackets for the control arms and shocks? I was checking out a bolt on application but quadratec seems pricey for a D44 that's direct bolt on. Again though, is this something I can accomplish in my garage at home with basic tools and will I need a machine shop help or special tools?
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Unread 05-22-2012, 01:51 PM   #10
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If you looking at 44s from q-tec might as well check out an 8.8 from ECGS . I got mine with 4.10 and a lock right bolt in ready for around $1500 I think
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Unread 05-22-2012, 01:52 PM   #11
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Quote:
Originally Posted by HootenTJ View Post
Can I assume if I decide to go with a Ford 8.8 I would need someone to weld on jeep TJ brackets for the control arms and shocks? I was checking out a bolt on application but quadratec seems pricey for a D44 that's direct bolt on. Again though, is this something I can accomplish in my garage at home with basic tools and will I need a machine shop help or special tools?
Yes, the 8.8 will need setup for the TJ coil and link suspension.

Or you can buy ready to bolt in 8.8 axle assemblies from East Coast Gear Supply.
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Unread 05-22-2012, 01:59 PM   #12
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Keep an eye on CL for any D44 options that might pop up. You might get lucky like cfmiller58. If I had a turdy-5, I'd be looking at the ECGS 8.8 setup for sure.
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Unread 05-22-2012, 04:21 PM   #13
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Bought a 57k 8.8 freshened it up and had it under the jeep for 450$ plus I have 4 wheel disc... 8.8 all the way, show me a tj Dana 44 for that money and ill eat my 8.8. Start at one rotor and chow down the whole way to the other
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Unread 05-22-2012, 04:36 PM   #14
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Quote:
Originally Posted by hallsofstone View Post
In any event, this may be a good opportunity for you to regear.
x2. If you're going to have a new 8.8 or 44 built gear to 4.88.
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Unread 05-22-2012, 04:48 PM   #15
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I would look around for a used D35, they are cheap if you find one and a lot easier to find than a D44. You can probably run across one out of a 4 banger with the same gears so you would not need to regear.
Biggest question with yours would be if your R/P is bad, if so then you are getting into a lot more money, then comes up the question of gearing better. If you do that, since you are already buying it all and setting it up anyway, you will need to do the front as well, so then you are buying 2 sets of gears and set up.
As for special tools if you do it yourself, yes you will need a few to set up the gears.
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