yes I know, D35 are pieces of crap.....
I think that the pumpkin has rotated on the axle tubes. Every thing checks ok as far as sprinp perches, springs etc. Pinion is now pointing slightly above drive saft line. Think Ill spot weld the tubes to pumpkin and shim the spring/perch. Any other ideas????

Other than 60 60 60 60?

Weld those POS tubes to the center section. Spot welds wont do.

Oh yeah 44 44 44 44 <IMG SRC="smilies/thefinger.gif" border="0">

when I had that shitter ass axle I broke it while going off the curb in my wrangler oh yeah I only had 33's at the time and a 6cyl what a POS piss on dana 35's <IMG SRC="smilies/rainbow.gif" border="0">

you don't mean spot welded do you???

spot weld are for sheet metal.

MIG TIG ARC is for axle tubes.

if you mean filling in the holes through the casting, that's called a PLUG weld.

ok then tig weld it. But looking at the "heaftyness" of the D35 axle tub, maybe spot weld was ok. (sh*tmetal.

cut off the perches instead of getting shims, shims will break and spit out. That leads to big problems! also what seems to be the excepted method of welding tubes to the housing is several 1-1.5 inch welds arounf the tube, not just solid weld all the way around.

Oh yeah where in Nebraska you at, I just clicked on this post cause I saw "Bugeater" <IMG SRC="smilies/biggrin.gif" border="0">

FAWK it just spot weld the bieeeech

Spot weld, I just fell out of my chair. I was laughing so hard...

Thank you that just made my day. <IMG SRC="smilies/bounce.gif" border="0"> <IMG SRC="smilies/bounce2.gif" border="0">

ne roktoy - Im from Beatrice. Think I may have seen you going through town heading to Kansas??

Actually I think the tubes are "puddle welded" to the housings.

there are holes in the housing and a puddle of weld material is applied to the tube through those holes.

this does not imply that the weld material added actually adheres/penetrates/sticks
to the center section.

If you are going to attempt to weld the tubes to the center use a rod suitable for welding cast iron (it'll "stick" better)
And use a "stich" method, do short sections (1/2-3/4" at a time)

But in general you'd probably be better off looking for another housing.

Good luck,

AllanD

Originally posted by Bugeater:
<STRONG>ne roktoy - Im from Beatrice. Think I may have seen you going through town heading to Kansas??</STRONG>

no my truck is down for the ocunt right now, trying to get a shop right now so I can get the truck up and running. It sucks working in a 1 car garage!!!

Get an axle truss for your Dana35, and get the super35 kit from Superior Axle and Gear. I heard that only one person has broken one of those shafts, and he was in some ARCA event (maybe not the 35 kit, maybe the super44 kit) That should make that weak Dana35 considerably stronger.

Originally posted by crawlin'YJ
Get an axle truss for your Dana35, and get the super35 kit from Superior Axle and Gear. I heard that only one person has broken one of those shafts, and he was in some ARCA event (maybe not the 35 kit, maybe the super44 kit) That should make that weak Dana35 considerably stronger. psst......... Go read the "Jeep talk mission statement" again concering D35's.....

Welcome Newbie :flipoff2:

BTW, thanks for the good laugh too! :laughing:

psst......... Go read the "Jeep talk mission statement" again concering D35's.....

:flipoff2:Hello "Rock God":flipoff2:
I already have read the Jeep Mission Statement
But I think If he is only runnin 35's, then he would be fine with the Dana35.
Just my .02 for people who don't have a surplus of money to go buy custom-built Dana60's front and rear.

:jeep:

Unfortunatly ive already invested $$$ into my D35, Locker-4.88 gears. So Ive got to make it last as long as i can. No, Idont baby it, but do keep in mind that my rear end is the weak link. So I dont do to much hard stuff where it would be almost impossible to get pulled back to the trailer. :D
However, my wife is pretty understanding. I do see a 9" sometime in the future:) :) :)

if you have that much invested in your axles, hop over to JU and find a newbie sucker to buy those pos's........then grab a 44 front and rear or 44 front and 9 inch rear for the same $ you sold your 35 for.

oh and crawlin yj.............:flipoff2:

super 35 kit?
bwahahahahahahahahahahahahahahahahahaha:laughing:


you better go re-read the statement. :rolleyes:

No matter how much you truss up, weld onto, full float, or otherwise fart around with a D35 you still have teeny tiny gears.

True, but he's only sitting on 35's. He's not gonna compete in the Goodyear Rockcrawling Championship. If you have money to do it, go with the biggest you can find.
Oh, and mkbruin,
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:flipoff2:didn't I see you in that event?:flipoff2:
:rolleyes: :laughing: hahahahahahahahaha

I nuked 7 Dana 35's and I only was running 33" tires......
And I only had 4:10's... With 4:88's you aint got much pinion in there....

Although I simpathize with your plight.......... Hmmmm.

OK, it's friday and I'm bored. So I'll chime in here.
Yes, I admit it. I dumped cash into a fawking 35 too. Many years ago now. And it held up remarkably well to my current suprise. But there is no doubt about it... dumping cash into a 35, and I'll state it again for the record, is like polishing a turd.

IMHO don't truss it, don't spend another dime on it. Weld the fawker up, shim it and get by on it and save your $ for some real axles. Just keep it clean so when you ARE ready to swap in the goods, you can sell it quick on JU. :D

Let me get this straight....We're defending the honor of the dana 35 axle....we're talking about trussing the thing.....

am I fawkin dreaming here, or did someone snatch the ballsack from POR???

I can't believe that this thread isn't on fire right now.....

Originally posted by Beezil
Let me get this straight....We're defending the honor of the dana 35 axle....we're talking about trussing the thing.....

am I fawkin dreaming here, or did someone snatch the ballsack from POR???

I can't believe that this thread isn't on fire right now.....

Umm, Beezil, not to go pissing on your parade here, but didn't you contemplate swapping the D35 from your rolled XJ into your CJ? I know you have the same 44 as me right now, but I distinctly remember reading on your site that you salvaged the XJs axles :flipoff2:

I ran a Dana 35c with 36 inch tires for a long time while I was searching for an upgrade, I locked the 35c, and wheeled it like I had stolen it. NEVER had any issues. I am not saying that that axle is a GOOD axle, but if You know how to freakin drive you can go anywhere you want. Ofcours I am a RockCRAWLER and not a trail Baja racer.