Pre Build Question: 89 Jeep XJ Axle/Locker Combos

[Curtis2010]

I have an 89 XJ which I am about build out as an overland vehicle. For this use a torsen rear differential sounds like a good option (already have an Aussie Locker for front). However my rear axle is a Dana 35, which seems pretty universally loathed.

My question is should I swap out the Dana 35 for something more robust, like a Dana 44?, or is the 35 reasonable for overland type use with a torsen diff?


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[darthyota]

I would at minimum try and find a Dana 44 perhaps a fully upgraded on that a JK guy is trying to sell to fund his Dana 60 swap.

 

[Vertigo]

Better solution since your XJ has leaf springs is a Ford 8.8 from an Explorer. Endless gear options, strong, leaf sprung from 90-94, same bolt pattern (5x4.5) and nearly identical track width as the Dana 35.

 

[Jbig117]

I have an 89 XJ which I am about build out as an overland vehicle. For this use a torsen rear differential sounds like a good option (already have an Aussie Locker for front). However my rear axle is a Dana 35, which seems pretty universally loathed.

My question is should I swap out the Dana 35 for something more robust, like a Dana 44?, or is the 35 reasonable for overland type use with a torsen diff?


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I have a 93 XJ with a dana 35 but i dont do much that would stress the D35. At some point when i start caring a ton of gear and doing more offroad i will look into the D44 or a Ford 8.8. my biggest concern for the swap is my skill level for the mount up. I dont know how to weld... :(

 

[Curtis2010]

I will also add the Ford 8.8 to my list. Options are good since I dont know for sure what I will find here. No shortage of good welders though.

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[Jeff Graham]

Like @darthyota mentioned, JK axles are a good option. I'm upgrading my JK to Prorock 44 front with RCV axles, and Prorock XD60 rear. I'm repurposing my old JK into a XJ. The shop quoted $1k to move the spring buckets Front (upper and lower control Arms are good). Convert the rear to except the leaf springs. I'm sure we will run into a couple of additional issues, but still a drastic increase in strength over stock axles on XJ.