Need your thoughts on going from a dana 35 to an 8.25?

[dagod16]

Any problem doing this swap? Any concerns? Or is this just an easy swap?
What about the transfer case, any worries after the swap with the transfer case?

Thanks

[Mudderoy]

Any problem doing this swap? Any concerns? Or is this just an easy swap?
What about the transfer case, any worries after the swap with the transfer case?

Thanks

Do you have ABS?

[dagod16]

No idea if I have abs. Abs is the pumping my brakes make correct? It doesn't pump at all on the brakes. I do all the work.

[4.3LXJ]

No, it is an antilock system. If you have them there will be sensors on the axle and a box with lots of brake lines going out of it under the hood

[dagod16]

Ok I do not have abs then

[bluedragon436]

If you don't have ABS, as long as you pickup a 8.25 with the same gear ratio as your front axle then you should be good to go, it is a bolt in axle if it's out of a XJ..

[ArmyGuy45]

If you have ABS like me then that leaves you in a pickle. You have to deal with an ABS light with the 8.25 or go the Dana 44/ Ford 8.8 route.

[dagod16]

nope, no ABS.

So is the 8.25 better or worse. Tell me the bad and the good. Will it swap right into place? Do we need welding?

[Brasscatz]

The 8.25 is a stronger axle. Some of them even have limited slip, which is desirable. There really aren't any cons to it and it's direct bolt in, no welding or any modification needed.

[xj-jake]

No I'm fairly certain if you have a Dana 35 you have ABS in your Jeep. I'm sure Steve will jump in here put I'm pretty sure the 8.25 in the late models were the only way to slip the ABS.

[abebehrmann]

If you have the thing outlined in red then you have ABS.

[dagod16]

I DO NOT have ABS brakes. So does this mean the swap could be a piece of cake?

[xj-jake]

From Wikipedia...

http://en.wikipedia.org/wiki/Jeep_Cherokee_(XJ)#Rear_axle

Rear axle[edit]
1984–1989: Dana 35, non c-clip, with anti-lock braking system (ABS) or non-ABS.
1987–1991: Dana 44, models w/tow package only, 30-spline axleshafts, non-abs.
1990–1996: Dana 35, c-clip, ABS or non-ABS.
1997–2001: Dana 35, c-clip, ABS.
1991–1996: Chrysler 8.25", c-clip, non-ABS, 27-spline axleshafts.
Late 1996–2001: Chrysler 8.25", c-clip, non-ABS, 29-spline axleshafts.



According to this if you have NO ABS now, you have a Chrysler 8.25 axle already.

Snap a photo of the housing for us that will solve the question of which axle you have for sure.

[NW99XJ]

I HAVE Seen D35's w/o ABS... there's always exceptions to the rule...
To be absolutely certain DAGOD16 could post up a picture of the area around his master cylinder and we can verify this...
If it DOES end up that there is no ABS system on this Jeep, then yes... the 8.25 axle WILL be a direct bolt in with ZERO changes/modification needed, and can be done with basic hand tools.
THE ONLY THING THAT YOU MAY HAVE TO WORRY ABOUT ....
Is the driveline... The 8.25 pinion is a bit longer than the D35 (iirc)
Its probably not enough to worry about, but just be aware of it...
To remedy this, you could hunt down a driveline out of the junk yard from an XJ that had the same tranny as you but with the 8.25 axle.... this is of course your worst case scenario.... the most important thing to verify is the gear ratio... if you get an 8.25 that has a different gear set than your front... the first time you put it into 4wd... you'll grenade the t-case.

[xj-jake]

Josh is correct on the driveshaft length and if I remember correctly its only about 1-2 inches different and you COULD possibly get by with the factory driveshaft.

[Mayooo]

Well besides the c-clips.. I love my 8.25!! And I beat the crap out of it..

[dagod16]

I will get a pic and post this morning.

[Mudderoy]

I DO NOT have ABS brakes. So does this mean the swap could be a piece of cake?

I know you're sure, but would you humor me and acknowledge you saw the picture (from Jake) above and you DO NOT have that under your hood on the driver's side?

I only ask because I don't want us to advise you it will be drop in and bolt on where there will be more to it.

[dagod16]

Sorry for the late post. Three times a year i have horrible backpain and i cant do anything.
Im away from my muscle relaxants and it hurts to even walk.

Attached pic shows no abs.

Im excited about this swap. My dana 35 has been grinding even after repairs for 200,000 miles.

[Mudderoy]

Sorry for the late post. Three times a year i have horrible backpain and i cant do anything.
Im away from my muscle relaxants and it hurts to even walk.

Attached pic shows no abs.

Im excited about this swap. My dana 35 has been grinding even after repairs for 200,000 miles.

No worries, I have a bad temper (at times) and I don't have back pain. My wife would say I'm a pain in the back though! :D

Well there are bearings in the 8.25 that you might want to replace, but then again you could do that after. I know when we upgraded my gears new outer bearings were about $30. Oh and change the diff oil. I would think the most difficult part of the job would be bleeding the breaks.

[dagod16]

Actually an xjtalk member is selling me the rear end, with new bearings on both sides with new seals, it should be like a new install.