My Dana 35 is going in my 97 and I was checking out an 87 Dana 44 to swap over but have also found a 99 8.25 which should have the 29 spline shafts. I am running 33x10.5s so it should be strong enough and discs are an easy swap but from what I have read I have a few questions. I have about 3-3.5" of lift and am running an Iron Rock Hack and Tap with a stock XJ front shaft, this should still be okay with the longer pinion of an 8.25, right? Also I believe the tubes are bigger so I will need the 8.25 u bolt plates and u bolts as well, right? or can the D35 u bolt plates be drilled out to work? Also I think I read the 8.25 uses a 1330 series u joint, is this correct as my D35 uses a 1310 so I would need to run a conversion u joint on my rear shaft or can I swap the yoke over from the D35 to the 8.25? The brakes on the 8.25 and D35 are the same right so I can swap over parts if I get an 8.25 without brakes I can use my D35 stuff till I get the parts for a disc swap. And yes I have searched and can't find exact answers to all these questions so any help would be great as I need to get a rear ASAP.
dharmabum
The XJ D44 and the D35 have the same size axle tubes, so you can use the same u-bolts for them. The 8.25 uses different sized u-bolts, so they won't swap over from a Dana 35.
You should never re-use u-bolts. They're designed to stretch when you first torque them down upon installation, so when you remove them you should replace them with a new set. With that being said, some people do re-use them without any negative effects - I wouldn't recommend it.
The stock XJ D44 or 29-spline 8.25 would be plenty strong for 33" tires. I run a stock XJ D44 on 33x12.50's and haven't had any issues at all.
Swapping discs one either the 8.25 or the D44 is easy enough. I did a disc swap on my XJ D44 using all Ford 8.8 parts - works fine. The D44 will require 2 sets of spacers that are necessary.
The front XJ driveshaft in the rear with either the 8.25 or D44 will work just fine.
I believe that they all use the 1310 u-joints.
The drums on the D35 and 8.25 are not the same IIRC, so no they won't swap over.
You should never re-use u-bolts. They're designed to stretch when you first torque them down upon installation, so when you remove them you should replace them with a new set. With that being said, some people do re-use them without any negative effects - I wouldn't recommend it.
The stock XJ D44 or 29-spline 8.25 would be plenty strong for 33" tires. I run a stock XJ D44 on 33x12.50's and haven't had any issues at all.
Swapping discs one either the 8.25 or the D44 is easy enough. I did a disc swap on my XJ D44 using all Ford 8.8 parts - works fine. The D44 will require 2 sets of spacers that are necessary.
The front XJ driveshaft in the rear with either the 8.25 or D44 will work just fine.
I believe that they all use the 1310 u-joints.
The drums on the D35 and 8.25 are not the same IIRC, so no they won't swap over.
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