D30 and 35- Why the most discarded axles on earth?

[92DripCherokee]

What weaknesses in the Dana 30 and 35 axles make them infamous for being unreliable?

[Kittrell]

It's not, the Dana 35 is...............:D

[goodburbon]

My 30 is because it keeps breaking. shafts, ring gear, bearing caps.

I didn't bother polishing the 35. 27 splines, c-clips, 7.58" ring gear, 2.62" axle tube.
What is there not to hate?

[XJoshua]

I dunno if I just havent pushed my dana35 hard enough yet or I got one of the stronger ones on the market. But I used to do plenty of nueteral drops some of which tore the driveshaft off but never hurt the axle. The frame has also knocked the axle more then a few times and who knows how many times Ive jumped curbs and slide into curbs.

So far its not bent and runs like a champ still. Only thing that need replaced one of these days is the bearings because they are starting to whine but Im sure this is from normal wear and tear.

[Kittrell]

What is there not to hate?

The factory paint job was tits.............:D

[goodburbon]

:thumbup: Dude, totally tits.:thumbup:

[schmiedel]

Well, I don't think they're weak, they're just built for stock setups, and bigger tires and offroading cause too much stress on them (specially on the D35).

People wheeling with very big tires and full-size vehicles might think that D44s are too weak for them, but they're not too weak for most XJs.

Regards

[crasy1_69]

you mean you guys don't like chyslers disappearing paint. :lol:

[goodburbon]

you mean you guys don't like chyslers disappearing paint. :lol:

They did that on purpose?!?! Someone call David Copperfield, he's demoted, we found someone who can make stuff disappear better.:thumbup:

[boise49ers]

Well, I don't think they're weak, they're just built for stock setups, and bigger tires and offroading cause too much stress on them (specially on the D35).

People wheeling with very big tires and full-size vehicles might think that D44s are too weak for them, but they're not too weak for most XJs.

Regards
Good point ! Though my parents went thru Three 35s in 5 years with a stock XJ that never went off road or towed anything. Not real sure what that was all about. I never got to work on it because they lived in Cali and then got fed up and dumped it.

[sloppyjoe]

I don't like d35's either but I will give it to them. It took me bouncing(I mean jumping in the air too, not to mention crushing the rockers in) my Jeep up the Kodiak section of uhwarrie just to break an axle with 4.56's and 33's. I guess it just goes to show that now and again they might hold up(not really) I would not trust them much though. I see nothing wrong with a hp30 though, love that axle. JOE>

[KarlVP]

Which line on Kodiak got you to bouncing? If you do it right, you can drive a stock suzuki sidekick up it.

[sloppyjoe]

Well there is a big 4ft wall right up the middle, I did not have a traction aid in the front and that is what really got me going, but the simple fact that I had never broke anything, and really would not give up led to the break. The middle line is quite big and I never have and never will see a stock anything go up it. A good friend of mine tried with 31's on a grand (ZJ), no luck not even close to having enough approach. I am not saying that a lifted Zuk can't do it b/c they r strong in there own, but stock...... Just ain't happnin. JOE>

[boise49ers]

I love XJs , but Zukes are the shit. Little money makes them King of the Rocks.
They call them Cheap Jeeps for a reason. They took first and second on the Wild Course at our Fun Crawl a couple weeks ago.

[Matthew Currie]

I once tried unsuccessfully to jerk a Chevy pickup out of a ditch with a chain, using the factory bumper hitch of my 87 XJ. The truck did not budge. I don't think it even jiggled. The hitch did not break or bend, but both axle shafts bent. There's a narrow part right near the pumpkin end, and they bent right there. Does that count as a weakness?

[boise49ers]

Yeah , but of the mind. You used Chain ? ?

[Fairmonco]

I beg to Differ...I used to have a Ranger....and I must say that Dana 28 SUCKS!!

[92DripCherokee]

So these axles were designed for "light duty" with OEM wheels and tires, and lack the beef needed to withstand higher torque and loads?

I have "beginners" axles? great.

[RichP]

Really nothing wrong with the 30 and it's easy enough to find an 8.25 29 spline and swap that in. Find one with either your gears or some other ones and build it before yo swap it. Add a traction device, disc brakes, the works before you even install it. It's just the 8.25 is easier to find than a D44.
OR
Go to currie and order two new 44's or 60's ready to go.... :D
Depends how deep your pockets are..

[Matthew Currie]

Yeah , but of the mind. You used Chain ? ?

Yeah yeah, I know. It happened at the time that a chain was what was at hand. I grew up using chain. Chain is cool. When it breaks it just drops to the ground instead of flying all over the place killing people. I forgot for a moment that it wasn't a Scout. If I'd had my old Scout the chain would have been the weak spot. I once used logging chain with the Scout to pull stumps. When I was done, the stumps were out and the Scout was fine, but the chain links had stretched so much that the chain would no longer fold.

Lesson learned. The bulldozer gets the chain, the Jeep gets the strap.

[stevez]

Moral to the story...
If you see a Chevy stuck just leave it there.
2nd moral of the story...
If you don't like rust color, you shouldn't have bought a jeep
(just my 2 cents worth)

[j99xj]

The well know failure "modes" for the dana 35c are:

Large diameter tires
really low gears
any locker
careless use of the gas pedal

But there are a couple other things that I think contribute GREATLY to the failure of dana 35s.

Lowering your tire pressure off road will increase the risk of breakage!

Yes, this increases "bite" and helps with traction but if one tire is on a 6 inch rock and the other tire is not, the radius from the axle shaft to the ground is 6 inches smaller, that means the differential will be placed under tremendous stress to compensate for the different radii, especially with a locker. I NEVER air down except for sand or if I'm stuck.

Another thing to think about is that wider tires and different backspacings (not just bigger diameters) can break the shafts too because they stick out much farther increasing the "moment arm".

[Blaine B.]

I've heard of D35's breaking with stock tires.

[Flyfisher]

OK...tired of hearing folks dis'ing the 30 and 35. I run an '89 XJ (Wagonner, 4.0L, with 242). I run 33" tires and routinely run low air pressure (8 lbs). I take it easy on the skinny pedel, and have never had a problem. I run a 3" skyjacker lift (with 1-1/2" rear shackle lifts) with a little fender trim. I think the stock axles are good...as long as you don't get too deep into the skinny pedel...that spin-and sudden stop-is what will break things. I've run rocks and snow...no problems yet.

[Blaine B.]

It's just that 100% power on the D35 (2wd mode) and large tires can hurt it.

The D30 may be just as weak, but when do you run it with 100% power? Can't unless you pull the rear DS and run 4wd, heh.

[j99xj]

I've heard of D35's breaking with stock tires.

I would bet that the operator was using too much gas pedal and was spinning the tires when one suddenly hooked up and broke something.

I don't have any numbers to back this up, but I'm fairly confident that nearly all the dana 35 failures occur when the axle is under power.

I've never heard of any axle breaking going downhill (expect when jumping, but your stupid if you jump your Jeep imho).

It seems that mechanical parts (axles included) always fail when under really high power/speed is applied. Other things contribute like what I mentioned in one of my last posts.


IF the dana 35 was truly a crappy axle it would fall apart as soon as you left the Jeep dealer's lot and would have been recalled immediately.

[8Mud]

I would bet that the operator was using too much gas pedal and was spinning the tires when one suddenly hooked up and broke something.

I don't have any numbers to back this up, but I'm fairly confident that nearly all the dana 35 failures occur when the axle is under power.

I've never heard of any axle breaking going downhill (expect when jumping, but your stupid if you jump your Jeep imho).

It seems that mechanical parts (axles included) always fail when under really high power/speed is applied. Other things contribute like what I mentioned in one of my last posts.


IF the dana 35 was truly a crappy axle it would fall apart as soon as you left the Jeep dealer's lot and would have been recalled immediately.

I've broken a lot of stuff on three XJ's over a 19 year period, but never managed to lunch a front or rear end. I have worn a few out though, bearings (pinion and carrier), spider gears and thrust washers.
What you said about the tires spinning and suddenly hooking up, is likely a large part of the failures. I've seen it often on most everybodies axles and U joints at the local mud pit.
The 30 front and the 35 rear may be a little light, but I usually drive my junk like I want to get there and back home again. The only rear I've ever luched, was an 8.25. I managed to over compress the driveshaft and flatten the collapsable sleeve, the pinion just kind of flopped around in there and jammed the ring gear, breaking off a couple of teeth. Too big of a bump, to much of a load in the rear and a driveshaft just a little too long. I've never run over a 30 inch tire on any of my XJ's. I did cork screw a D 60 axle shaft once, 383 big block Dodge PU.

[CanJeep]

I have had problems with the dana 30 axle probably just me being neglegent, i mean they were not meant to be launched through the air and slammed down. I run 37s with a 9 inch roughcountry/skyjacker lift and besides a broken front axle and bent tie rod end i have had no other problems. I run 37x13.50r15 bfg Krawlers with a welded up 35 in the rear with moser axles and beat the snot out of it, oh and it hold up just fine.

[goodburbon]

you win ;)

[aardvark4x4]

I've been abusing my 4.0HO 5 speed XJ on stock 30/35s with 3.73 for 2 years on aired down 31s and the only breakages I've had were entirley my own fault.
Exploded the spider gears in the rearend after the fourth full power attempt at a 1 in 1 climb with a big dip that launched the rearend airborne halfway up. Of course the Jeep landed, Bang! and I break the world land speed record for going backwards unexpectedly. Clean shorts required.
The only other faiure was a broken axle shaft UJ on the front during a similar ill advised stunt. launched the frontend skywards and busted the UJ on landing.
I think the stock axles are better than their reputation would suggest, and if you're not running 33+ tires and super low gears there is no need to upgrade unless you really want to. Just replace worn parts with upgraded when required. The only weakness on the street i have experienced in 10 years of servicing Jeeps is their appetite for bearings, but this is a wear rather than breakage issue, and with factory Trac-Locs, wear again rather than failure.
I've recently fitted ARBs to my XJ, which could show up weakness in the axle shafts, but have found that now I have these I have not had to use nearly as much brute force, so will probably continue to be reasonably trouble free.

[jeeperman1488]

you mean you guys don't like chyslers disappearing paint. :lol:




:shocked: u mean those things actully came with paint????:shocked:

[Ferrite]

I have broken a couple D35's...but it was more my fault than the axles, and it wasn't in an XJ.

I don't think they're as bad as (some) people make them out to be, BUT...

something I haven't seen mentioned in this thread yet...

If you break a shaft on the D35, your wheel/tire is going to leave the vehicle! You're done moving your Jeep until that axle shaft is replaced (in most cases, but there are always exceptions)

While it's a good idea, very few people actually carry spare shafts on the trail. My XJ isn't a DD, but I do like to be able to drive it home from the trails.

[EMSJEEP]

My D35 diff. failed last year, Easter Sunday. Bent the shafts in the housing, what was left of the diff. was in many pieces. Dealer had no interest in fixing it, just threw on a whole new one. (Hopefully that menas no too much is rusted back there yet and I will be able to take it off to do my lift!)

[goodburbon]

Dealer....last year? It was still under warranty?

[EMSJEEP]

Dealer....last year? It was still under warranty?

It was still under my 8year/80,000mile used vehicle warranty, they replaced all for $100 + a tow. I'm at 79,000miles now and getting a little nervous...

[Shorty]

If you break a shaft on the D35, your wheel/tire is going to leave the vehicle! You're done moving your Jeep until that axle shaft is replaced (in most cases, but there are always exceptions)

While it's a good idea, very few people actually carry spare shafts on the trail. My XJ isn't a DD, but I do like to be able to drive it home from the trails.[/quote]

Non C-clip shafts shouldn't loose wheel/tire. might have to pull cover and remove extra parts, but at least you can carry spare shaft/bearing/retainer and get home (with extra axle juice). usually, the damage is done after the breakage and it doesn't matter waht you HAD, the broken carrier will ruin a
perfectly good day!

more splines = more strength = longer life.

I'm a big fan of Ford 9" axles (unless they're 28 spline) as long as you are 33" or less.They'll take most anything you throw at 'em and keep pulling! Aftermarket shafts will even give them the strength to take more than they should!!!!

[UnDiEiNgBrEeD]

I know im late on the talk, but toward the start of this post.. a guy said he kept breaking things in his D35.. might want to swap it out... Buddy of mine has a YJ, and had a 35 in it, went through 3 sets of spiders... Finally got rid of the axle, he thinks it was bent.

[evil dead]

i know this thread is older but will a stock 30/35 combo last on 33's w/ a stick and 2.5

[BlackJax]

With the 2.5, I doubt you'll have a problem even on 35s as long as you don't bounce it or bind the axle u's.

[evil dead]

sweet...now how about welded:doh: