D44 outer onto D35, pros/cons

[Dishtowel]

If this is broken down in a previously posted thread, please point me in the right direction? Thanks

Running a wheezer 5.0L with a D35 front (4.88 gears) and worn out 36" Iroks. (measure about 33-34")

I'm running the $$$ heavy-duty 3lbs jeeprear hubs. They are awesome. I dont break hubs, I have to replace balljoints and tighten up bearings every so often. And the Spicer 5-760 joints.

Thus my weak point is the shaft u-joint ears. That is what I break.

I was reminded of Todds D44 outers swap as I was doing upper balljoints this weekend. I have a couple D44 TTB sets kicking around.

I'm using this thread as a sounding board for my decision to go ahead with D44 outer swap, or not to.

I would gain (pros):
Stronger/better balljoints,
Bigger better bearings,
Better brakes?
Stronger hubs?
Stronger out shafts? (But if I have stronger outs, I'll just be breaking inners = no gain)

Cons:
Work involved
marginal gains in problem areas?

Inputs? pls thanks

 

[Bent Bolt]

Outer D44 knuckles on the TTB D35 won't get you any stronger shafts. I think you either have to get some custom alloy shafts made or go SAS D60

or


Do the same funky D50 your buddy is running on that wild YJ !!

 

[Dishtowel]

Outer D44 knuckles on the TTB D35 won't get you any stronger shafts. I think you either have to get some custom alloy shafts made or go SAS D60

Not going to happen with this rig. Rig #2 is in the cooking pot right now...

Do the same funky D50 your buddy is running on that wild YJ !!

Now we're talking!! I already have a Stearling, and a D50.

 

[joshnlsn]

I have a d35 with d44 outers on it. The gains are, much stronger hubs and bigger wheel bearings. I would say go for it even if you have to buy some of the parts for the swap. It is much stronger and well worth it!!!

 

[Sasquatch_Ryda]

Pros:

Better bearings
Bigger brakes
Bit bigger balljoints

Cons:

Need to change wheels or run adapters

Really if you are breaking the ears on the shafts, this aint gonna fix your problem.

You running a front locker?

 

[CopyKat]

Clearancing the yokes for max angle helps. Along with adding a steering stop for the knuckle. The early D35's lack this.

I've only busted 1 axle shaft on my D35 and that was turning lock to lock when I was stuck in the snow, with a locked front.

 

[joshnlsn]

I have broken two shafts with mine. But that was before i used full circle clips for the u-joint and my caps would come out and the shaft would be ruined.

 

[Dishtowel]

If this wont help with breaking joint ears than it's not worth the time for me.

Bigger brakes would be nice
Bigger bearings = meh, this is a trail rig, and it gets trailer-ed if it has to drive on the road for more than 20 min.
Bigger ball joints would be nice, but I'll get over it, again, it does not see very many miles per year, and top ball joints are cheap and easy.

I know guys clearance the middle ujoint, but is it required on the outers? I'll have to look into that.....
(I dont have MAD flex, I get one tire 24-26" off the ground. Travel is even front/back)

Running an ARB up front
I had/have a mini spool in the 8.8, but I put a shift kit in my AOD, and now 1st to 2nd is a punch in the face shift. Hard on driveline, and was shearing the minispool apart, so it's welded in there, never to come out. One day when I break a shaft I might be air-arcing out the ball of weld that is my carrier cause I can't get to my c-clips anymore.
oops.

 

[4x4junkie]

Yeah like the others have said, D44 outers aren't going to help.

This might however

http://www.therangerstation.com/Magazine/May06/dana35_ujoint_snapring.htm

 

[joshnlsn]

If this wont help with breaking joint ears than it's not worth the time for me.

Hey Dishtowel, are you braking the u-joint and then trashing the shaft?

 

[Dishtowel]

Hey Dishtowel, are you braking the u-joint and then trashing the shaft?

The u joint cross is intact after the bad noises. Two caps are gone, and one shaft, or both, is ruined.

 

[joshnlsn]

I had that problem with mine, but the full circle snap rings fixed all my problems. If you have the parts do the swap. you will be very happy with the results, but you will have the same problems if you don't use regular snap rings for the caps.

 

[Dishtowel]

Duely noted.

 

[CopyKat]

I'm going on over 2 years now on my knuckle swap, and not once have I had second thoughts about the wheel bearings. I have retorqued them once before but that was because I changed the rotors. Everything else has been problem free.

 

[93 4x4]

I was thinking if I could take the d35 outers and put them on my d44 so I can use the disc brake set up Im running now and use the same wheels?

i know i would have to swap the upper ball joints, is there any thing else?