Weak Points of my Axle


Ranger44

Ranger44

15+ Year Member

Ford Technician
Joined
Aug 13, 2007
Messages
3,127
Points
3,101
City
Illinois
Vehicle Year
1995
Transmission
Automatic
I have a hybrid axle. I need to figure out how to build the rest of it, so I don't make the smaller ring and pinion the weak point of the axle. The biggest tires, I'd have on it are 32's, and the most power behind it would be a 3.0(It's 2.3 powered right now). I'm running it open.

Should I use regular Warn Hubs, or Jeep Hubs?

Anything else I should worry about, strength wise?
 
that tiny 6.6" ring gear is already a weak point. id say the only weaker item would be automatic hubs if you had them...if not, it'll be the R&P.
 
Well shoot. I may just try and find a 4.10 geared true 35 dif then. I bet my best luck would be from a 4cyl. They didn't start using hybrids till 93' right? So 90-92's would have a true 35 ring and pinion.
 
as far as i know, the hybrid has been an "option" ever since the d35 came out (1990)...so you'll atill have to make sure you find a true 35 and not another hybrid.
 
Ranger44 said:
Well shoot. I may just try and find a 4.10 geared true 35 dif then. I bet my best luck would be from a 4cyl. They didn't start using hybrids till 93' right? So 90-92's would have a true 35 ring and pinion.
Click to expand...
You are correct, hybrid didn't start until 93, I've got a nice 90 4 banger in the driveway with a 4.10 D35 I'll be taking shortly.
 
Hahnsb2 said:
You are correct, hybrid didn't start until 93.
Click to expand...

if your basing that solely on the fact that your '90 has a true 35 then it might not be correct. not ALL vehicles got the hybrid when it became available (it was an "option" i guess you could call it).

my '93 has a true 35.
 
It's hard to tell the hybrid from the D35 if you don't have a lot of hands-on with them. Ford calls the 'hybrid' a D28. But very few differences exist between the '93+ D28 and the '93+ D35. In fact, I would not swap out a 'hybrid' for a D35. There's nothing to gain. The only thing the D28 was bad for was the little toy u-joints. Even the hubs were strong compared to those things.

Weak Points of my Axle
 
Wicked_Sludge said:
if your basing that solely on the fact that your '90 has a true 35 then it might not be correct. not ALL vehicles got the hybrid when it became available (it was an "option" i guess you could call it).

my '93 has a true 35.
Click to expand...
No I'm basing it on all the other info that has been passed on here. As you can see, Will's chart clearly shows that it was D35 only between 90-92. Not all 3.0 trucks after 93 got hybrids, but a lot did.
 
Will said:
But very few differences exist between the '93+ D28 and the '93+ D35. In fact, I would not swap out a 'hybrid' for a D35. There's nothing to gain.
Click to expand...

Say what??

You don't think larger 27 spline shafts, the nearly 1" bigger ring gear, and the fact nearly any locker can be had for it are gains??
With the little u-joints gone, why wouldn't any of these now be the weak link? :icon_confused:


IMO, the hybrid D28's weakest point is going to be where the shafts neck down to 23 spline where they enter the diff. I wouldn't bother with the Jeep hubs unless you plan to swap the chunk out for a D35 in the near future.


Oh and yeah, no D28s between '90½-'93, hybrid or otherwise.
 
Last edited:
Well, I'm just going to search for a 4.10 D35 chunk. If I find one, I find one. Thanks for the help guys. If it comes down to it, should I look for a 4.10 8.8 also, to replace the 7.5? I want the axles to be on par in strength.
 
The 7.5" should be fine with 32s. Only if you want more locker and/or gearing options (or if you think you'll go bigger than 33s in the future) would it be worth grabbing an 8.8" also.
 
Well the biggest tires I would run would be 32's. I'm just going to run a lunchbox locker, like the lock rite, in the rear. The front will reamain open. I'm just going to look for a D35 pig, and if anything regear one to 4.10's or 4.11's.
 
My buddy has a 91 2.3 4x4 running 33s. It still has the stock 7.5 rear an has a d35 front factory. The only prolblem hes having is that He cant keep the front wheel berrings together with 14in wide boggers.
 
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