• Welcome Visitor! Please take a few seconds and Register for our forum. Even if you don't want to post, you can still 'Like' and react to posts.

Dana 35 carrier/housing upgrade


thcscubajohn

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.
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

New Member
Joined
Feb 28, 2017
Messages
75
Reaction score
0
Points
0
Location
NW Ohio
Vehicle Year
1992
Make / Model
Ford
Engine Size
3.0
Transmission
Manual
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

Ranger Custom
Article Contributor
OTOTM Winner
TRS Banner 2010-2011
Truck of Month
Joined
Aug 14, 2007
Messages
7,895
Reaction score
982
Points
113
Location
UT
Vehicle Year
1989
Make / Model
Ford
Engine Type
4.0 V6
Transmission
Manual
2WD / 4WD
4WD
Total Lift
5
Tire Size
33
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

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.

thcscubajohn

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.

4x4junkie

Forum Staff Member
TRS Forum Moderator
TRS 20th Anniversary
Joined
Aug 19, 2001
Messages
10,749
Reaction score
580
Points
113
Location
So. Calif (SFV)
Vehicle Year
1990
Make / Model
Bronco II
Engine Type
2.9 V6
Engine Size
2.9L V6
Transmission
Manual
2WD / 4WD
4WD
Tire Size
35x12.50R15
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.
 
Last edited:

thcscubajohn

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.
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

Forum Staff Member
TRS Forum Moderator
TRS 20th Anniversary
Joined
Aug 19, 2001
Messages
10,749
Reaction score
580
Points
113
Location
So. Calif (SFV)
Vehicle Year
1990
Make / Model
Bronco II
Engine Type
2.9 V6
Engine Size
2.9L V6
Transmission
Manual
2WD / 4WD
4WD
Tire Size
35x12.50R15
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

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.
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"

Sent from my SM-G950U using Tapatalk
 

4x4junkie

Forum Staff Member
TRS Forum Moderator
TRS 20th Anniversary
Joined
Aug 19, 2001
Messages
10,749
Reaction score
580
Points
113
Location
So. Calif (SFV)
Vehicle Year
1990
Make / Model
Bronco II
Engine Type
2.9 V6
Engine Size
2.9L V6
Transmission
Manual
2WD / 4WD
4WD
Tire Size
35x12.50R15
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

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.
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

Sent from my SM-G950U using Tapatalk
 

thcscubajohn

Active Member
Joined
Nov 23, 2014
Messages
148
Reaction score
31
Points
28
Location
Antarctica
Vehicle Year
1994
Make / Model
FORD
Engine Type
4.0 V6
Engine Size
247ci
Transmission
Manual
2WD / 4WD
4WD
Total Lift
4"
Tire Size
31x10.50r15
My credo
Smog is for pussies.
(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

Sent from my SM-G950U using Tapatalk
 

Sponsored Ad


Sponsored Ad

Staff online

Members online

Member & Vendor Upgrades

For a small yearly donation, you can support this forum and receive a 'Supporting Member' banner, or become a 'Supporting Vendor' and promote your products here. Click the banner to find out how.

Truck of The Month


Kirby N.
March Truck of The Month

Recently Featured

Want to see your truck here? Share your photos and details in the forum.

Follow TRS On Instagram

TRS Events

25th Anniversary Sponsors

Check Out The TRS Store


Sponsored Ad


Sponsored Ad

Sponsored Ad


Amazon Deals

Top