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Dana 28 TTB / Dana 35 TTB Specifications

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(Dana 35 Above / Dana 28 Below)

Ford Rangers appeared with a reverse cut Dana 28 TTB (Twin Traction Beam) 4WD front axle in 1983.  In 1990, Ford Introduced a 4.0L V6 to its engine lineup, and along came the larger Dana 35 axle to handle the increase in power. The Dana 28 didn't completely go away though.  A version of it found its way in to the 1990-1997 Ford Aerostar AWD mini-vans.  It also found it's way back in to the 4-cylinder (and some 3.0L V6) Ford Rangers from 1993-1997.  The 1993-1997  Rangers can be deceiving.  Some owners believe they automatically have a Dana 35 because they have a 1990 or newer Ford Ranger.  Although their 1993-1997 4-cylinder Ranger may look like it has a Dana 35, it may really be a Dana 35 axle beam using a special housing, and Dana 28 components.

In 1998, the Ford Ranger went to a Dana 35 SLA front axle.  The Dana 35 SLA switched from a reverse rotation gear to standard rotation gear.  The gears in a 1997 and older Ranger/Explorer will not work in the 1998 and newer Rangers.

 

Specification Dana 28 Dana 35
Ring Gear Diameter 6.625 Inches 7.56 Inches
Ring Gear Bolts   (8) 3/8" x 24 RH
Pinion Stem 1.312 Inch  1.406 Inch
Carrier Breaks 3.73 & up, 3.45 & down None (All D35 TTB gears use the "Hi-Ratio" (3.55 & up) carrier, regardless of ratio)
Axle Shaft Diameter / Spline 1.00 / 23 1.16" / 27
Bolt Pattern 12 Bolt Pattern On Front Of Axle 10 Bolt Pattern On Front Of Axle
Factory Ratios 3.08, 3.45, 3.73, 4.10 3.27, 3.55, 3.73, 4.10
Aftermarket Ratios 4.56, 5.13 (Discontinued) 4.56, 4.88 5.13
U-Joints 5-456x (1210 Series) 5-297x (stock), 5-760x
Max Tire Diameter Rating 31 Inches 35 Inches (TTB), 33 Inches (SLA IFS)
Pinion Bearing Preload 10 - 13 In Lbs (new)  6 - 8 In Lbs (used) 15 - 25 In Lbs (new bearings)  6 - 8 In Lbs (used)
Backlash 0.005-0.008 Inches 0.005-0.008 Inches
Ring Gear Bolt Torque 55 Lbs Foot 70-90 Lbs Ft
Carrier Bearing Cap Torque 30-45 Lbs Foot 47-67 Lbs Ft
Pinion Nut Torque 140 - 500 lbs-ft Foot (crush sleeve) 170 - 500 lbs-ft (crush sleeve)
Fluid 2 Quarts Hypoid Gear Lubicant SAE 80W or 90W 3 Quarts Hypoid Gear Lubicant SAE 80W or 90W
Exploded Views  & Part Numbers Click HERE Click HERE
Resource - Randy's Ring & Pinion

The below photos show the visual differences between the Dana 28 and Dana 35.

Click Photos For Larger Image

 

Dana Axle Labels:

Your front axle may have a code stamped on the left carrier arm between the fill plug and axle end.  It will look like 'F17A' or similar.  What this code represents is;

 E = 1980's 

 F = 1990's

 1 = Last digit of year

 7 = Ranger

 A = Light Truck Engineering

 (For more information on breaking down codes, click HERE.

Since the Dana 28's were built in the 1980's, their code will start with an 'E' where as the Dana 35's were built in the 1990's and will start with an 'F'.  The above mentioned code would indicate that the axle was a Ranger axle built in 1991.

There is a manufacturers label on the back side of the right axle beam that lists the year manufactured and gear ratio.

If you look at the top left of this sticker, you can see 610366 which identifies this as a:

610366 FORD 35 FRONT 1990 1/2-92 1/2 EXPLORER

The second box from top right identifies it as having 3.73 gears.

These stickers are on the back side of the passenger side axle beam.


Axle Shaft Comparison:

Here is a picture of a Dana 28 & Dana 35 driver side axle shaft with the dimensions shown.

 

Spindle Comparisons:

Here's a picture of a Dana 35 (Left) and Dana 28 (Right) spindle with dimensions shown.

 Connect to the Internet if you can't see this image.

Dana 35 Hybrid / Dana 35 Identification & Comparison:

 

The Dana 35 ~vs~ Dana 35 Hybrid Identification

Dana 35 Hybrid

Dana 35

(Click For Larger View)

In the above (2) photos on the left it shows a Dana 35 hybrid that houses the Dana 28 carrier/gears.  Note that the housing has a smooth surface.  In the (2) photo's on the right you'll see a true Dana 35 differential. Note how the case in the far right photo is ribbed for strength. 

The easiest way to check to see if your Dana 35, has Dana 28 "Guts", is to pull the fill plug out from the front. If you can see the main cap, you have the Dana 28 guts (Sorry!).  If you can see the end of the carrier, you have "The Real Thing".  If you click on the photos above of the carriers internals you'll see a red dot. This marks the location of what you will see through the "Plug".

Note that the Dana 35 Hybrid has a smooth bottom

 

Ranger 4WD Front Axle 'Build of Material' Numbers:

 

610171 FORD DANA 28 FRONT 1983-1984 RANGER
610223 FORD DANA 28 FRONT 1984 1/2-1985 RANGER/BRONCO II
610249 FORD DANA 28 FRONT 1986-87 RANGER/BRONCO II
610298 FORD DANA 28 FRONT 1987 1/2 RANGER/BRONCO II
610300 FORD DANA 35 FRONT 1990 RANGER/BRONCO II
610307 FORD DANA 28 FRONT 1988-1989 RANGER/BRONCO II
610365 FORD DANA 35 FRONT 1990 1/2-92 1/2 RANGER/BRONCO II
610366 FORD DANA 35 FRONT 1990 1/2-92 1/2 EXPLORER
610410 FORD DANA 35 FRONT 1993-1994 1/2 EXPLORER ABS
610418 FORD DANA 28 FRONT 1993-1994 1/2 RANGER (Hybrid axle)
610419 FORD DANA 35 FRONT 1993-1994 1/2 RANGER
610436 FORD DANA 35 FRONT 1992 1/2 RANGER
610437 FORD DANA 35 FRONT 1992 1/2 EXPLORER
610476 FORD DANA 35 FRONT 1995 EXPLORER - DISCONNECT (SLA IFS)
610483 FORD DANA 35 FRONT 1995-1997 1/2 RANGER ABS
610484 FORD DANA 28 FRONT 1995-1997 1/2 RANGER ABS (Hybrid axle)
610556 FORD DANA 35 FRONT 1998 EXPLORER - NON DISCONNECT (SLA IFS)
610581 FORD DANA 35 FRONT 1995-1996 EXPLORER - DISCONNECT (SLA IFS)
610582 FORD DANA 35 FRONT 1995-1996 EXPLORER - DISCONNECT (SLA IFS)
610585 FORD DANA 35 FRONT 1996 EXPLORER - NON DISCONNECT (SLA IFS)
610586 FORD DANA 35 FRONT 1996 EXPLORER - NON DISCONNECT (SLA IFS)
610642 FORD DANA 35 FRONT 1998-1998 1/2 EXPLORER - NON-DISCONNECT (SLA IFS)
610643 FORD DANA 35 FRONT 1998-1998 1/2 EXPLORER - NON-DISCONNECT (SLA IFS)
610644 FORD DANA 35 FRONT 1997 1/2 EXPLORER - NON-DISCONNECT (SLA IFS)
610645 FORD DANA 35 FRONT 1998-1998 1/2 EXPLORER - NON-DISCONNECT (SLA IFS)
610652 FORD DANA 35 FRONT 1997-1997 1/2 RANGER
610653 FORD DANA 28 FRONT 1997 RANGER NON ABS (Hybrid Axle)
610774 FORD DANA 35 FRONT 1999 EXPLORER - NON-DISCONNECT (SLA IFS)

From the above, we can see BOM #s:

  • 610418

  • 610484

  • 610653

Are the Dana 35 "hybrid" axles with the Dana 28 guts.

This number can be found at the top-left of the label located on the backside of the passenger side axle beam. For SLA axles, it will be on the passenger side axle tube

Upgrades:

If you have the Dana 28 there isn't much available to upgrade your axle.  Powertrax makes the Lock-Rite locker for the Dana 28 and Precision Gear makes gears up to a 4.56 ratio.

If you have the Dana 35, you have a few more options:

Manual Hubs - You can upgrade to a set of Warn manual Jeep hubs for the Dana 35.  Click HERE for more info.

C-Clip Eliminator - The c-clip that holds the axle in the passenger side of the differential can be eliminated (required for some lockers, and also makes shaft replacement on the trail much easier).  Click HERE for more info.

Dana 44 Knuckle Swap - This swap involves replace the Dana 35 steering knuckles with knuckles from a Dana 44 and using the bigger brakes, hubs, etc. The main key thing here is the axle benefits of the 35/44 hybrid. You'll have 1/2 ton outers meaning you have better hubs, wheel bearing spacing and larger rotors and calipers then on the Dana 35. 

Shaft wise, the Dana 44 stub shafts are larger than the stub shafts on a Dana 35. It's interesting to note, that the Dana 44 shafts have a neck-down on them that tapers down to 1.09" inches. The smallest point on the Dana 35 shafts is 1.16" inches where it tapers down to go in to the carrier. The only shaft on a Dana 35 that is smaller than the neck-down on the Dana 44, is the Dana 35 stub shaft, which is 1.0625" inches. Therefore, swapping the Dana 44 stub shaft on to a Dana 35 will actually result in a axle assembly with larger axles than the Dana 44.

The image above and below shows where the Dana 44 TTB axle shafts taper down to 1.09" inches. That's smaller than the Dana 35 shafts.

To see how to do this swap click HERE. The hubs will be a 5 on 5.5 wheel pattern which means you'll need adapters for the rear axle so you have the same wheel bolt pattern on all (4) wheels.

Steering Upgrades - Superlift makes a Superrunner steering kit that replaces the stock steering. It has virtually equal length arms to eliminate the bumpsteer.

 

30 Spline Axles - PowerTrax has developed a special Lock-Rite locker, available only from Superior Axle & Gear (888-522-2953) for the rear Dana 35 that installs in the stock Ranger Dana 35 carrier and accepts a 30-spline axle.  Detroit Locker also offers a 30-spline locker for the rear Dana 35.  They were originally designed as an upgrade for the Jeep Dana 35-C rear axle to accept Superior Axles 30-spline axle kit.  The Dana 44 TTB has 30-spline inner axle shafts that will fit in this locker.  The shafts are too long and will need to be cut down.  Currie Enterprises (714-528-6957) can do this and says that the axle housing may need machined to accept larger differential seals.  The Dana 44 TTB uses a different outer Knuckle and brake design and it's outer stub axles can't be used.  You will need to use the stub axles from a 1991 and up 4.0-Liter Explorer which has the same U-Joints as the Dana 44.  This will allow the use of the factory knuckles, brakes, and locking hubs.  The larger axle shafts will give you a 30% increase in strength.  

ARB now offers P/N RD105 and Detroit Locker offers P/N 162C66A 30-spline lockers for Dana 35's.

U-Joint Snap Ring Upgrade - Click HERE to see an article on a snap ring upgrade.

Skid Plate - DynaTrac (714-898-5228) manufactures a skid plate that bolts on to the Ranger TTB front axle using the factory carrier bolts.  It's designed to protect the axle from impacts without losing ground clearance.

Replacement Shafts - Jeff Bronco Graveyard carries replacement axle shafts for the Dana 35 HERE.

Things To Watch:

Bearings - Ranger TTB axles are known for bearing problems (particularly when using wide-offset wheels).  You should keep a close watch on your wheel bearings to make sure they haven't loosened up or become damaged from overheating.  If you wheel your Ranger and carry spare parts you'll probably want to carry a spare hub and wheel bearings.  The stock hubs are prone to break from hard wheeling and the wheel bearings could go out on you somewhere between the trail and home due to debris, heat and working their way loose. Loosening of the bearings can be minimized by torquing the outer bearing locknut to 225 ft-lbs instead of the book spec of 150.

TTB Axle beams - A few cases of cracked beams have been reported right at the end of the welds on the backside of the passengerside beam with prolonged hard offroad use. If you use your truck hard (such as rockcrawling), some reinforcement in this area (I.E., boxing up the open backside of the beam) can improve it's durability here. Also, NEVER run with a missing pinch bolt behind the radius arm on the driverside axle beam. Cracking of the beam around the lower radius arm bolt hole can result if you do.

The Whole Front Assembly:

(Dana 28 front axle beams, radius arms, and crossmember)

 

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