The standard axle used in the 1997 through 2006 Jeep TJ Wrangler was the Dana 35. There were a few options available from the factory that used the Dana 44 Axle but there were very limited numbers of these produced. The 1984 through 2001 Jeep XJ Cherokee used the Dana 35 and the Chrysler 8.25” Axles. Again there were a few options produced that used the heavier Dana 44 Axle. The Dana 44 is a great axle and will withstand a lot of abuse. The Dana 35 Axle is a great axle for stock applications but once the higher gear ratios and larger tires are installed, the Dana 35 Axle will not hold up to the additional abuse.
Dana 35 Differential Cover
One of the most popular axle swaps is the Ford 8.8 out of the 1995 through 2002 Ford Explorers. This axle came sock with 31 spline shafts and discs brakes. The axle tubes are 3.25”. This larger surface area provides plenty of surface area for installation of spring buckets or perches depending on the vehicle. The lug pattern is 5 on 4.5”, the same as the TJ Wranglers and the XJ Cherokees. The disadvantage to these axles is that they are a c-clip axle and are approximately .75” overall narrower than the Dana 35 used on the Jeep TJ Wrangler and XJ Cherokee.
Ford 8.8 Differential Cover
The Ford 8.8” Axle can be modified to fit the style of driving you desire. The c-clip axles are not desirable, for off road applications, due to the added side stresses that are encountered with the various terrains.
Yukon Gear and
Superior both offer a C-Clip Eliminator Kit for the Ford 8.8” Axle. These kits come complete with 4340 Chromoly Axles. The flanges are double drilled for either the 5 x 4.5” or 5 x 5.5” bolt patterns. This gives you the option to run the standard Jeep Wheels used on the Jeep Wranglers and XJ Cherokee or the larger bolt pattern used on the early Jeep, Ford and Dodge Vehicles.
Yukon Gear C Clip Eliminator Kit
Superior C-Clip Eliminator Kit
There are several different online companies that provide the necessary components such as spring buckets and perches to adapt the Ford 8.8” Axle to fit in your vehicle. They can be found on all the major forums.
The Ford 8.8 Axle can be easily updated with a Spartan Locker for added offroad performance.
Spartan Locker
Here is a list of general specifications comparing the primary differences between the Dana 35 Axle used in the Jeep Wranglers and Cherokees and the Ford 8.8″ Axle used in the Explorer.
| |
Dana 35
|
Ford 8.8″
|
| Width between WMS |
60.5″
|
58.75″
|
| Ring Gear Diameter |
7.625″
|
8.8″
|
| Ring Gear Bolts |
8 – 3/8″x24
|
12 – 7/16″x 20
|
| Cover Bolts |
10
|
10
|
| Carrier Breaks |
3.31/3.54
|
None
|
| Pinion Splines |
26
|
28
|
| Pinion Diameter |
1.375″
|
1.625″
|
| Axle Splines |
27
|
31
|
| Axle Diameter |
1.16″
|
1.31″
|
| Gear Ratios |
3.07 – 4.88
|
3.08 – 6.14
|
| Pinion Offset |
.75″
|
2 3/16″
|
| Axle Tube Diameter |
2.5″
|
3.25″
|
| Brakes |
Drum
|
Disc
|
4WD, 4x4, 8.8 Axle, Cherokee, Ford 8.8 Axle, Ford Axle, Four Wheel Drive, Jeep, Jeep Cherokee, TJ, Wrangler, XJ, XJ Cherokee, YJ
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