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Topic: D35 vs 8.25

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ChevelleSSLS6
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D35 vs 8.25
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A buddy of mine has a non-DD XJ... chopped roof and tailgate like a lot of them have once they make the DD to trail rig jump.

His axle is a D35, non C clip, with an Aussie locker in it.

He recently got his mitts on some heavier duty axles (I think a D44 front and a D60 rear or something... anyways, its not important for this discussion), and I wonder if it'd be good to buy his locker'd 35 for my XJ.

Will the driveline angles change any between the 8.25 currently installed (slight vibes around 30) and the D35?

The whole '8.25 vs axle X' thing has been beaten like a pile of pulp of what was a dead horse.  Gross.  If anyone feels like enlightening me on the differences of D35s beyond the "D35 c-clip uses c-clips to hold the axles in place and is supposedly somehow weaker because of this".

I plan on keeping my 31s and 3.5" lift, so I really don't need any super awesomeness hardcore axles.

Thanks,
Matt

EDIT:
I did find this... the super 35 sounds interesting for something to save up for (after the rust and stuff is fixed)
http://www.jpmagazine.com/techarticles/16722_building_dana_35/index.html

-- Edited by ChevelleSSLS6 on Wednesday 3rd of November 2010 02:26:09 PM

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90XJkid
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From what I have read and understand the c-clip factor has nothing to do with strength. It is the diameter of the axle shaft and the quality of the metal. I have a D35 in my rig and would love to have a traction aid in the rear, but have read and been told its a bad idea. It depends on your driving style how long a locked 35 will last. Also, like many have said, get out and wheel your XJ you will be surprised what open diffs will do. I know I have been blown away by where I can climb and what I can flex through. If you have the 29 spline 8.25 maybe look into an Aussie for that if you are looking for a locked rear end.



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ChevelleSSLS6
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Shortly after swapping out the D35 for the 8.25 about a year ago, I got Jeep stuck after parking it on ice. One wheel on ice and the other on dry pavement. Flat driveway. Jeep wouldn't move, and would just spin the 31" BFG AT (lotsa tread left).

Not feeling like giving it gas to melt the ice to get traction, I had to put it into 4wd just to move it, lol. I knew no vehicle worthy of the Jeep name should go through the shame of getting stuck on a smooth driveway due to being parked on a patch of ice.

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My Fleet
1996 XJ "Snowball"- 3.5" lift, bunch of little mods.  I hate pegleg rear axles!
1974 AMC Javelin "Jade Grenade"- 360v8, 4sp, green inside and out. Underfunded Project.
2009 Kawsaki Vulan 900 "Rocket III"- Summer DD
Bigtrucknut
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I wouldn't swap out the stronger 8.25 axle for a D35 regardless of the fact that the D35 has a locker. You didn't say but I assume that the gear ratio in the D35 is the same as your current axle? I suggest you save the money you planned to use to buy the D35 and put it toward one of the lunchbox lockers for your current axle. Thay are not very expensive and are relatively easy to install. The Aussie Locker is about the least expensive I've seen of the lunchbox lockers at $335 from Motion Offroad.

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'98 XJ Sport: 4 1/2" lift, Rusty's lower control arms and tracbar riding on 265/75-16's
'00 WJ Laredo 2 1/2" lift
'73 CJ5: Chevy 350, NP435, D20 w/TeraLow gears, locked D44/D30 with 4.27s
'45 GPW: Stock
'88 Dodge Ramcharger: 360, NP435, NP241, D60s on 37 TrXus MTs
'04 Ford Excursion: PSD 6.0L on a mild lift
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First off we need to clearify a few things;

  • The D35 found in the XJ's were available in 2 different forms. One was WITH C-Clip's (1990-2001) and one was WITHOUT C-Clips (1984-1989).
  • The 8.25" was also found in the XJ's in 2 different forms. One with 27 Spline Shafts (1991-1996), and one with 29 Spline Shafts (1997-2001).
  • The D35 axle shaft (1.18") is actually larger than the 27spline 8.25" axle shaft (1.17"). The only advantage the 27spline 8.25" has over the D35 is the size of the ring gear (8.25" vs. 7.58").

Now I don't want to get in a huge debate on what one is better or not. But based on my experience I would personally take a NON C-CLIP D35 over a 27 spline 8.25" anyday of the week. The only way I'd swap in a 27 spline 8.25" axle into any XJ is if it had the factory Trak-Loc limited slip in it.

I have ran a un-locked NON C-Clip D35 axle with 35" tires without issues on 3 different Jeeps (both daily driven and wheeled) and have not had any issues. I have also ran a un-locked C-Clip D35 with the same 35" tires and have broken several shafts.



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