YJ Lift Rear Ubolts - JeepForum.com
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post #1 of 13 Old 09-27-2017, 09:16 AM Thread Starter
Donzshots
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YJ Lift Rear Ubolts

Anyone out there still have the Dana 35 on the rear of their wrangler... what is the diameter of the axle tube? I have small zone lift kit that came with 2.5in ubolts that will not fit the rear! It measures 2.62in. I have another Dana 35 I measured and it also is 2.62in... but yet Zone Offroad is telling me they have never had any issues installing their kit and the correct size is 2.5in. The small side of the Dana 30 on the front fits that. It can't be a coincidence I have 2 rear axles both at 2.62.





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post #2 of 13 Old 09-27-2017, 09:30 AM
bpounds
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I remember having to adjust the U-bolts a little. I just took a hammer and vise and banged them to fit. Did not seem like a big deal, and something I expect with press formed parts like those. I did not actually measure anything.

Bill
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post #3 of 13 Old 09-27-2017, 11:44 AM
Jeepsr4me
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That amount is so small I would just press the Ubolt on and forget about it... It will stretch very easy and not cause any issues...
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post #4 of 13 Old 09-27-2017, 04:11 PM
Luuca
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The rear U-Bolts are larger Diameter:

The Rubicon Express Kit has the Proper sizes you need; here are the details off the Morris 4x4 site: https://www.morris4x4center.com/u-bolts-rub-re2421.html

Important Notes:

Dana 35 Rear Axle
Fits:

1987-1995 Jeep Wrangler YJ
1984-2001 Jeep Cherokee XJ
Description:

Rubicon Express U Bolt kits contain 4 bolts with nuts and washers and are zink plated for corrosion resistance. Complete u-bolt kit for Dana 35 Rear Axle. U-bolts are clear zinc plated

Product Details:

Clear Zinc Plated
Dana 35 Rear Axle
Thread: 1/2"
Size: 2.625"x 6.5"
Parts Included:

(4) U-Bolts
(8) Washers
(8) Nuts
Years Covered:

1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000 and 2001

You can BFH the wrong size on or get the correct size for the application. Up to you. I bought this U-Bolt Kit for my kids jeep and everything went smoothly.

91 YJ "Alice"
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post #5 of 13 Old 09-27-2017, 05:01 PM
bpounds
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You're not building a piano. Just use a little persuasion.

Bill
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1988 Wrangler,4.2L I-6, Howell EFI JP-1,CRT HEI Ign,AX15 ext slave conversion, Zone 2" lift + 1" BL + 1/2" booms, BFG 31 x 10.5, Bestop.
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post #6 of 13 Old 09-27-2017, 05:09 PM
Luuca
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Quote:
Originally Posted by Jeepsr4me View Post
That amount is so small I would just press the Ubolt on and forget about it... It will stretch very easy and not cause any issues...
Which is thicker, the U-Bolt or the Axle Tube? Which will give when force is applied while torquing the 4 bolts to the plate?

Quote:
Originally Posted by bpounds View Post
You're not building a piano. Just use a little persuasion.
What happens if the U-Bolt breaks loose? What happens if the axle tube gets bent/cracked?

Yes, it's a jeep. If there were no more correct sized U-Bolts in the world, I say 2.5 is close enough, but the correct part is available. "you always have the time and money to do it right the second time."

91 YJ "Alice"
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post #7 of 13 Old 09-27-2017, 05:17 PM
shaggyjim
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I have a place in town called The Spring Works that I go to and have them made. 9/16th super beef and done the right way to whatever size I need. Look around your town and I bet you will have 4x4 shop, RV place, or trailer shop that can make you some too.
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post #8 of 13 Old 09-27-2017, 07:33 PM Thread Starter
Donzshots
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Order up

Appreciate all the comments.

As much as I would enjoy beating the crap out of the bolts at this point to make them fit I am going to order the bolts and have them fit properly. Just pisses me off that the kit does not include the correct ones or the company will not honor and exchange for the correct ones. Should have known better than deal with fleabay anyway!

As a matter of fact I am going to put the stock ones for now since I am going to replace the rear axle anyway.
The other 35 I have is built out as a super 35 with 30 splines and a detroit locker with disc conversion which I am going to sell to offset some of the cost of a 44 or 8.8 axle/locker setup and I am sure those will be different sized ubolts/plates anyway so will order then.
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post #9 of 13 Old 09-27-2017, 10:00 PM
Mr.B
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Quote:
Originally Posted by shaggyjim View Post
I have a place in town called The Spring Works that I go to and have them made. 9/16th super beef and done the right way to whatever size I need. Look around your town and I bet you will have 4x4 shop, RV place, or trailer shop that can make you some too.

Yeah, I had a local shop custom make my 8.8 bolts. Well it was about 30 miles away. It cost me about 2/3rds the cost of ordering online. And it only took them about 20 minutes.
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post #10 of 13 Old 09-28-2017, 03:09 AM
rja1766
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My local NAPA had the right size for my 8.8 when I put on my new springs recently. They were a little long so had to cut off the excess. If I recall, they were about 7 -8 dollars per bolt/nut/washer.


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post #11 of 13 Old 09-28-2017, 03:48 AM
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Quote:
Originally Posted by Mr.B View Post
Yeah, I had a local shop custom make my 8.8 bolts. Well it was about 30 miles away. It cost me about 2/3rds the cost of ordering online. And it only took them about 20 minutes.
Where is this?

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post #12 of 13 Old 09-28-2017, 06:26 AM
Mr.B
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I don't remember exactly. It was some machine shop off Power Inn Rd., in South Sac County. A couple of my neighbors that were into racing, recommended them.

.
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Quote:
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post #13 of 13 Old 09-28-2017, 08:30 AM
bpounds
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Quote:
Originally Posted by Donzshots View Post
...As much as I would enjoy beating the crap out of the bolts at this point to make them fit...
I was being somewhat facetious about using a big hammer. In fact, it is ridiculously easy to open these up. We're talking about 2.5" versus 2.63", so 1/16" difference in the radius of the bend.

Ridiculously easy as in, take a couple of pieces of 1/2" water pipe and slip over each leg of the bolt. Spring it apart slightly. Drop the bolt over your axle tube, put the pieces of pipe back on the legs and spring them together. The important part is that they have to fit the hole pattern in the original clamp plate, so you'll have a gauge. We're talking 2 minutes per bolt max.

I agree that sourcing bolts local is a great idea, but you bought a kit, so you already bought bolts that will work perfectly. This was such a nothingburger that I didn't even know the diameters were slightly different. Just dealt with it, like lift kits always require a bit of.

Bill
Jeepers drive high!
1988 Wrangler,4.2L I-6, Howell EFI JP-1,CRT HEI Ign,AX15 ext slave conversion, Zone 2" lift + 1" BL + 1/2" booms, BFG 31 x 10.5, Bestop.
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