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Dana 35 carrier/housing upgrade

thcscubajohn

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Hello Ranger rangers, I am in the process of building a monster and need some suggestions. Im working with a 94 4L (soon to be a 4.3) gonna use everything Tom Morana makes for the ohv. The expected output is~ 450 ft lbs and im going to probably use a tremec viper 6 speed with a first gear ratio of 2.97:1 I'd like to use the atlas 4 speed with a lowest range of 10.39:1 with 3.73 R&P so the final torque on the front axle in lowest range in first will be 23,309 ft lbs at 90% efficiency. A bit much for the stock d35 w/ 27 splines, no? Anyway what I want to do is keep the TTB IFS system as this gives the ranger its unique style, but need the information of someone that can make a 31 or 35 spline D35 3rd member. Or another idea that would work RELIABLY. I called Spicer and they had no ****ing idea how much torque stock can handle. I may just need to ditch the TTB IFS and swap in a solid D44 ultimate or maybe a D60 ultimate. I only want replies that contain solutions, not problems. If your solution is to swap in a solid front end please don't even reply that is the last resort not the first choice I really want to keep the TTB. Thanks TRS community.
 


Kurt.king870s

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Maybe look into swaping in a d44 beam axle......I think they came in earlier 90s f-150s, maybe 80s as well. It would take some work, but that would be way stronger than that d35, and it would still be ttb. I believe there are also d50 and d60 beam axles, but those would probably be harder to find.
 

BlackBII

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450ft-lbs from a 4.3 seems optimistic.

But, from the tech library..

The heaviest version of the TTB system was the Dana 50 TTB used on F250HD (over 8500# GVW) trucks and '80-'85 F350s. This system uses a Dana 50 model differential w/ 9" ring gear. The same axle housings are used for both the Dana 44HD and Dana 50 TTB systems, so the only difference between them (out to the spindles) is the differential. There were actually two different versions of the Dana 50 TTB. The lighter Dana 50 TTB used the same components as the Dana 44HD TTB on F250HDs from 1980 to 1983 or so. The heavier version used somewhat bigger axle shafts, u-joints, spindles, bearings, hubs, and hub lockouts on F350s and later model F250HDs.
http://www.therangerstation.com/tech_library/Dana44TTB.shtml
 

thcscubajohn

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thcscubajohn

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4x4junkie

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30 spline Dana35 carriers exist, leaving you with only having to source some 30 spline stub shafts and Warn hubs for the outers (or maybe swap to D44 outers). I haven't heard of anything for a D35 with bigger than 30-spline though (and probably for good reason, the D35 R&P gears would likely become the weak link before any shaft bigger than 30 spline).

Something else I'd probably suggest since you're talking torque numbers, is put a couple bearing cap load bolts on the beam (cover), stiffening it up with some gussets where needed (or maybe a D35 girdle cover for a Jeep axle exists? (I haven't checked), which you could probably fit by cutting the front part of the beam open for it.

If you decide to go with a full-fledged D44, look for a '80-'96 ½-ton axle (avoid '87 with the hat-style hubs though). This would be far easier to swap in place of your D35 than a ¾-ton axle would be. The D50 centersection should fit the ½-ton axle beam as well.
 
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thcscubajohn

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30 spline Dana35 carriers exist, leaving you with only having to source some 30 spline stub shafts and Warn hubs for the outers (or maybe swap to D44 outers). I haven't heard of anything for a D35 with bigger than 30-spline though (and probably for good reason, the D35 R&P gears would likely become the weak link before any shaft bigger than 30 spline).

Something else I'd probably suggest since you're talking torque numbers, is put a couple bearing cap load bolts on the beam (cover), stiffening it up with some gussets where needed (or maybe a D35 girdle cover for a Jeep axle exists? (I haven't checked), which you could probably fit by cutting the front part of the beam open for it.

If you decide to go with a full-fledged D44, look for a '80-'96 ½-ton axle (avoid '87 with the hat-style hubs though). This would be far easier to swap in place of your D35 than a ¾-ton axle would be. The D50 centersection should fit the ½-ton axle beam as well.
What applications does the D35 30spline have? I am concerned that even 30spline will be too weak especially if it isn't one piece. 450ftlbsX2.97:1 1stgear ratioX10.39:1t-case lowest ratioX3.73:1R&P ratio=51,796ftlbs, split between 2 axles is 25,898 to the front at 90% efficiency is 23,308ftlbs. This is why im using a 35spline trutrac ford 9" in the rear instead of my first choice, a 31spline torsen t2 8.8, the 31spline shafts aren't strong enough they're only good to 21-22k ftlbs before they become a routine maintenance item.
 

4x4junkie

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Remember that your tires will normally slip and lose traction LONNNNNG before torque could ever build up to anything close to those numbers (those numbers would only be possible if the axle was connected to a steel rim strapped down and welded solid to a 1" thick steel plate that your entire truck is parked on... Or maybe if you wedged a tire deep under a large rock outcropping, in which case you'd easily be able to feel something is bound up and it's best to back off the throttle). A fully-built Dana60 with 35 splines and chromos throughout would also succumb to those numbers if the tires were unable to slip at all (same for your 35-spl 9" too).

If I were to use similar math on mine (taking away the torque split since I also have a locking diff that is capable of sending everything down one side), I'm only a little below your numbers (170ft-lbs × 3.72:1 × 2.48:1 × 2.48:1 × 5.13:1 = 19,953ft-lbs). (Knock on wood) I've not had any axle breakage issues (at least not since my young adulthood years where I flagrantly abused the truck by launching it over rough terrain at full throttle anyway, and I broke U-joints more often than I did at the splines).

The 30-spline D35 differential is an aftermarket upgrade for the rear axle of many Chrysler-built Jeeps from around '87-'06. Since the TTB D35 uses the same differential unit as the Jeep axle, it will fit the TTB axle as well.

What size tires are you planning to put on this thing anyway?
 

thcscubajohn

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I plan to have a set of 30" road tire(slicks), a 32" highway tire, and 33 or 35 inch off road tire probably both a 35" rock tire and a 33" sand/mud I am currently leaning towards a d44 ttb swap, keep the extra width and mach it with the 9"

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4x4junkie

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It's unlikely you'll have any issues with a 30-spline front axle (and probably even the 27 spline as well). Lots of guys (inc. myself) run 35" offroad tires on the 27 spline D35 w/o issue.
 

thcscubajohn

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3000 ft lbs is the difference of needing a 31 spline and a 35. If I ever pull/push some [emoji90] on the pavement with a 10.4 low range ratio you can bet I'm going to maximize traction with the wheels barely turning. Not to mention if I ever use the 2wlo feature. everything on this truck is overkill the engine will only hopefully put out 450 ft lbs hopefully with mad boost, the trans can handle 700. there can not even be the possibility of failure under any circumstances that's the goal. 25000lbs is what my output would be if measured by your formula 5000 ft lbs would be enough to lift the truck off the ground(ma

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thcscubajohn

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(Might exceed 5500 lbs gross so maybe 5500ft lbs) that is a lot of force and I would rather spend more finance now than time later I've learned that in the automotive industry that preparation is everything

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