though i haven't had a problem with it yet it's my understanding that the wheel bearing design of the 35 is flawed and will spall the axle shaft upon failure which is eminant if you run mud and water. i stay out of the deep stuff tho...

The dana 35 is what is called a C-clip Semi-float axle. The semi-float means that the actual axle shafts are taking the weight of the vehicle (no independent wheel bearings like front axles or big work trucks). The c-clip means that the axles are retained by c-clips in the spider gears. ALSO on a c-clip axle, the bearing is not pressed onto the axle shaft. instead, the outer race and rollers are pressed into the axle tube, and the inner race is the axle shaft itself. There is a hardened polished section of the axle shaft that take all the up/down force. If a bearing fails, It always takes out this hardened section because it is the race. When this happens you get to replace the bearing AND the axle shaft. That is one of the reasons the d35 is hated so much.

1. You snap a shaft, nothing is holding in the axle anymore and the wheel and what is left of the axle falls out.
2. If/When the axle bearing fails, it takes out the axle shaft with it.
3. Weak axle tubes
4. Itty bitty (or cute) internals.

They both suck, get a 9".

You will have to forgive GS...He must wheel in a dump truck!
Big JIm <img src="/forums/images/graemlins/pfft.gif" alt="" />

While we are learning how crappy D35s are, I noticed that one of the most common explinations why,is that it has c-clips. Ok, what about the 87-90 D35 that are captured bearing, ie no c-clips? One thing I can vouch for is the side and pinion spider gears are still crap. I had my cover off recently (filled er up w/ water <img src="/forums/images/graemlins/smile.gif" alt="" />) and noticed some rather large chunks out of them. This rearend has 3.07 gears in it(I run 33's) and the races and gears have slight pits in them so I sourced a pair of axles w/ 4.11 gears but it will have c-clip axles. I am doing this to tie me over while I decide wether to go 8.8 Ford (This will be far the cheapest route) or find an SJ w/o Quadratrash to steal the D44s. I tried to elaborate on the original topic to keep from jacking the thread.
So should I build the captured bearing D35 w/new gears or just put in the c-clip axle assembly and spend the money on the befier axles. BTW not locked and don't plan to lock any D35.

BTW to answer the original question, 3.07 and 33's can be driven but SUX, you have to slip the clutch off the line more or bog the motor. It is wheelable in low range on the t-case. If you want to go 33's w/ 3.07, I say yes...Why, because it will be just enough of a pain to drive to make you upgrade the ratios(gears) soon as you can. DO NOT lock a D35 w/33's w/o some sort of upgrade minimum. 31spline axles, Super 35 ect.

Please read number 3 and 4 above... non c-clip axles are a hair better.

Before I swapped out my d35, I never had an axle breakage or wheel bearing failure. It was all the itty bitty (cute) internals takin a dumb that got me.

I was not sure if the "cute internals" were exactly the same. Well until I get the axles I want, that is what is going to be under my YJ. I will not bother fixing the captured bearing D35, I will just put in the c-clip rear and start the search for better. I just can't stand these 3.07s in this Jeep any more. Probably will go 8.8 Ford, easy two shim setup, and I have all the axle shafts I will ever need. <img src="/forums/images/graemlins/nana.gif" alt="" />

ok, so for example, a 4.0 yj with a 30 up front and a 44 out back should be all but bulletproof? or 44's front and back is better, a 60 is too much unless your running like some 44 inch monsters....

[quote]ok, so for example, a 4.0 yj with a 30 up front and a 44 out back should be all but bulletproof? or 44's front and back is better, a 60 is too much unless your running like some 44 inch monsters

i wouldn't call it bulletproof.

Nothing is bullet proof. If you decide to pop the clutch in reverse on hard ground in 4x4 with a dana 30 and 33's you'll probably break something. Will the dana 30/44 combo hold up to 33-35's with lockers and medium agressive trail riding? Yes.