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4 Wheel Drive/SUVs/Wrangler 1999, Sahara

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Expert: - 4/26/2004


Question
Carl,

I own a 1999 TJ Sahara, the d-35 in the rear failed, spider gears broke and that took a hunk out of the ring gear.  I can take it to one of 3 local Jeep dealers and have it fixed or I can purchase an entire d-44 rear off e-bay, there are a number of them. I don't go off road much but I would very much like to begin. The price of the d-44's are around $1,500, one has 20K miles with brakes and drums, the other is new but has no brake assembly.  So, if I do buy the new d-44 without brakes can I use the brake assembly from the d-35?  So any advice would be helpful.  Oh I guess I could also repair the differential myself, never did one but I'm somewhat mechanical.

Thanks
Bill

Answer
Bill,

If you plan on doing any hard core off roading, the dana-44 would be much better than the dana-35.  One of the problems with the 35, is that the axle tubes are quite thin, and prone to bending.  If you go with the 44, make sure that the wheel bolt pattern matches your stock pattern.  This should be 5 lug on a 4 1/2" pattern.  I would, also try to find one that has disk brakes.  I would recommend that you contact some of the custom suppliers, such as Currie Enterprises, and price some of their units.  The cost may be a little more, but they will build a rear end specifically for your TJ.

There are several other companies that sell heavy duty components for your dana-35, along with dana-44's, and Ford 9" rear ends.  I would suggest that you purchase a couple of off road magazines, such as 4-Wheeler, or JP, and check out their ads.  Another company that sells components, and publishes a free magazine called Off-Road Adventures is 4-Wheel Parts Wholesalers.

I would review these ads, and give some of the suppliers a phone call.  Most of them have technicians available, and they are, usually willing to discuss your needs.

  Carl  

4 Wheel Drive/SUVs

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Carl Brandt

Expertise

Will discuss suspensions, lifts, lockers along with tire suggestions. Trail ratings and possible requirements needed for specific type of trails. Safety equipment and what you should carry with you. Certified off-road instructor. I am not a mechanic, and 4-Wheeling is a hobby, so if I can't answer a technical question it is due to my mechanical knowledge being related to vehicles that I have owned, or have worked on. I do not have manuals on all vehicles.

Experience

40 plus years of 4 wheeling in a variety of vehicles. At the present time, my major off-road rig is a 94 Jeep Wrangler with a spring over and a 1 1/2" suspension lift. This gives me a total lift of 7" or so. I have lockers front and rear. I have removed the track bars, and sway bar for maximum articulation. I am running a stock 2.5 ltr 4 cylinder with a Jacobs ignition along with a cold air high flow filter. It has 4.56:1 gears with a Dodge NV4500 transmission along with a 3.8:1 Atlas II transfer case. This gives me a final ratio of 105:1 in low gear/low range. Other vehicles I own, are a 96 Ford F-250 with a 6" lift, posi rear end, 36" Hummer tires, 5 speed with a fuel injected 460 ci engine, an 87 Samurai with an 8" lift, Ford 9" rear end with a spool, Chevy Dana 44 front end with an electric locker, 5.88 gears, 16% reduction in high range and a 6.5:1 low range with 35" Baja Claws, and a stock 2003 Grand Cherokee Overland. Trails I have run are the Rubicon (10 times), Dusey Ershim, Fordyce Creek trail, McGrew trail, several trails in Moab, Utah along with local monthly runs.

Organizations
Lost Coast 4x4's Cal 4-Wheel Corva UFWDA Blue Ribbon Coalition

Education/Credentials
Certified off-road instructor - Certificates in engineering/electronics

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