Swapping out the Dana 28’s

[vonD1025]

So I’m injured and don’t really feel like hittting pick n pull with a bad back. Does anyone know where to get a good set upgrades without killing my wallet? Not sure if I want to go to the Dana 35 or 44. Still torn between upgrading to 33” tires or 35” but from everything I’ve been reading it seems the Dana 28 won’t hold up on 33’s..

Thanks everyone

 

[4x4junkie]

Very sharp looking BII. Lots of potential there.
Yeah there's been a few here who have broken the tiny Dana28 u-joints & shafts on tires barely bigger than stock (like 30s).

The Dana35 from a 1st-gen Explorer or '90-'97 Ranger would be by far the easiest swap, and should handle 35" tires no problem. It bolts in place of the D28 other than you may need to shorten the front driveshaft an inch or so (if you have a suspension lift, it's possible you may be able to get away w/o shortening the driveshaft, but check to make sure).

33s are about the limit for the 7.5" rear. If you're thinking 35s, you'll want to snag an 8.8" from a 1st or 2nd-gen Explorer. This swap requires a little bit of welding and a new driveshaft, but otherwise is not difficult to do (needs the leaf spring mounts relocated, and shock mounts put on it).

Some info here:

The Ford Ranger Dana 28 & Dana 35 Front 4x4 Axle

www.therangerstation.com

Ford Ranger Dana 28 / Dana 35 Axle Swap

www.therangerstation.com

The Ford Explorer 8.8-Inch Axle Swap

www.therangerstation.com

 

[bobbywalter]

normally....in the before times....i would be the first one to lineup and shoot the d 28 in the face....








these days...with normalish power and 33 inch tires i would be tempted to just buy good joints fromspicer and the aftermarket shafts...the newer shafts are pretty good. fair price and bolt in.


the ground clearance of the d28 and lighter weight make it worth the time to roll the dice and see if its livable.

here is a link..

https://shop.broncograveyard.com/Dana-28-Axle-Shafts/products/1034/





never thought i would post a reason to keep a28.. the end is nigh......

 

[vonD1025]

Very sharp looking BII. Lots of potential there.
Yeah there's been a few here who have broken the tiny Dana28 u-joints & shafts on tires barely bigger than stock (like 30s).

The Dana35 from a 1st-gen Explorer or '90-'97 Ranger would be by far the easiest swap, and should handle 35" tires no problem. It bolts in place of the D28 other than you may need to shorten the front driveshaft an inch or so (if you have a suspension lift, it's possible you may be able to get away w/o shortening the driveshaft, but check to make sure).

33s are about the limit for the 7.5" rear. If you're thinking 35s, you'll want to snag an 8.8" from a 1st or 2nd-gen Explorer. This swap requires a little bit of welding and a new driveshaft, but otherwise is not difficult to do (needs the leaf spring mounts relocated, and shock mounts put on it).

Some info here:

The Ford Ranger Dana 28 & Dana 35 Front 4x4 Axle

www.therangerstation.com

Ford Ranger Dana 28 / Dana 35 Axle Swap

www.therangerstation.com

The Ford Explorer 8.8-Inch Axle Swap

www.therangerstation.com

Thanks! Yeah I have 30” tires on now. It does really well and I don’t believe it has any lift. I don’t get any rubbing when turning or any issues bottoming out. Thanks for the links. Lots of reading to do.

Do you know will a jeep Dana axles fit the Bronco 2’s? I found a Dana 44 front and Dana 60 rear the guy wants 400$ for both.

newbie when it comes to doing this so thanks for the help. Also what do you think about just upgrading the Dana 28 parts to hold 33’s like bobbywalters suggested?

 

[vonD1025]

Ye

normally....in the before times....i would be the first one to lineup and shoot the d 28 in the face....








these days...with normalish power and 33 inch tires i would be tempted to just buy good joints fromspicer and the aftermarket shafts...the newer shafts are pretty good. fair price and bolt in.


the ground clearance of the d28 and lighter weight make it worth the time to roll the dice and see if its livable.

here is a link..

https://shop.broncograveyard.com/Dana-28-Axle-Shafts/products/1034/





never thought i would post a reason to keep a28.. the end is nigh......

Ive got the 2.9 in there and the only things I really planned on upgrading is the air intake and adding a performance chip to fix the fuel/air ratio. Supposedly it gives you about 8mpg more and adds 60hp. I’m not to heavy footed unless I hit a mud patch and when in doubt throttle out. Really think it would be worth it to upgrade parts and then be safe on at least 33’s

 

[scotts90ranger]

Jeep axles can "fit" but require a fair amount of modification, the TTB D35 is a much simpler swap (really only a handful of bolts aside from the driveshaft shortening issue, but that can be fixed by grabbing the 1354 transfer case and front drive shaft and shifter while you're there...)

 

[bobbywalter]

I would try the aftermarket axles. Jim ran the d28 for many years with a 302 and auto trans. Good axleshafts were not an option back then .

These are my critters. Just took these pics a little while ago. Dana 60 in the ranger...and 44 in the broncojeepinator. One has a v8 diesel and auto...the other a 4.0 and a manual.

I am not kidding when I say keep the 28 with 33' in tires and mild use. Broncos are incredible stock.

 

[scotts90ranger]

I'm with Bobby, wouldn't hurt to run as is for a while, as long as you aren't airborne or applying high power with the wheels cranked on a high traction surface it's likely not an issue. I ran a turbo 2.3L with roached U joints in the D28 for a couple years on 31's without issue (didn't know the joints were shot until I pulled the axle) and have yet to break a front axle in the D35, but I mostly play in sand anymore...

 

[4x4junkie]

Thanks! Yeah I have 30” tires on now. It does really well and I don’t believe it has any lift. I don’t get any rubbing when turning or any issues bottoming out. Thanks for the links. Lots of reading to do.

Do you know will a jeep Dana axles fit the Bronco 2’s? I found a Dana 44 front and Dana 60 rear the guy wants 400$ for both.

newbie when it comes to doing this so thanks for the help. Also what do you think about just upgrading the Dana 28 parts to hold 33’s like bobbywalters suggested?

I guess it all depends on how it's driven/where you intend to go. A D28 would probably last about 100 feet into the trail under my rig lol.

What I would suggest if you want to try sticking with the D28 (rather than dump $$$ into it that might go to waste), weld the u-joint caps to the axle yokes (check/grease them first because servicing them afterward will be tough). This can add significant strength that they wouldn't have otherwise, and is essentially free. Though it still would be well short of the strength of the D35, it may be enough for it to stay together under mild/moderate use (fire roads, mud, snow, etc.). If it breaks, then all you're out is a little bit of time and welding rod or wire & gas or whatever it may be.

Other axles do not fit under a BII without significant cutting and fabricating things... Unless you have some suspension engineering knowledge (and a good 220V welder), I'd suggest save that type of swap for a later date.

 

[vonD1025]

Super torn on what to do here. I plan on some pretty heavy off roading. Plus adding more weight on by getting new bumpers and winch rooftop tent. Probably smarter to just move up at that point.

Have to say that after yesterday and almost rolling my little buddy that those D28’s hold up pretty well!! Rear end slid out on me coming down a snowy/muddy hill. I was able to wrench the wheels to the right before I dropped into a little wash out. Probably would have broke an axle if I wouldn’t have corrected as I slid. Second pic didn’t do the drop justice but it was a good 2+ft drop. Held up under the weight of being up on 2 tires and half way on its side. No damage to the body thankfully !! Wish I would have got pics in that position but I probably would have rolled if I got out..

Alright so my question is now what donor vehicles should I be looking at for the Dana 35 or Dana 44 and I should switch the rear to an 8.5?

 

[vonD1025]

Just reread some stuff and I meant 8.8. But what from?

 

[vonD1025]

Very sharp looking BII. Lots of potential there.
Yeah there's been a few here who have broken the tiny Dana28 u-joints & shafts on tires barely bigger than stock (like 30s).

The Dana35 from a 1st-gen Explorer or '90-'97 Ranger would be by far the easiest swap, and should handle 35" tires no problem. It bolts in place of the D28 other than you may need to shorten the front driveshaft an inch or so (if you have a suspension lift, it's possible you may be able to get away w/o shortening the driveshaft, but check to make sure).

33s are about the limit for the 7.5" rear. If you're thinking 35s, you'll want to snag an 8.8" from a 1st or 2nd-gen Explorer. This swap requires a little bit of welding and a new driveshaft, but otherwise is not difficult to do (needs the leaf spring mounts relocated, and shock mounts put on it).

Some info here:

The Ford Ranger Dana 28 & Dana 35 Front 4x4 Axle

www.therangerstation.com

Ford Ranger Dana 28 / Dana 35 Axle Swap

www.therangerstation.com

The Ford Explorer 8.8-Inch Axle Swap

www.therangerstation.com

I should go to bed you wrote everything down for me... Brains not working and all I can think about is building this Bronco up

 

[bobbywalter]

explorer 8.8.....and ttb d35

 

[Shran]

I did some dumb things back in the day with a D28 and 33's... I am actually surprised that I never broke anything. I did, however, break a lot of D28 hubs and shafts on another truck that was basically a tough truck type deal...we kept it around for doing donuts in the snow and jumped it over snow banks and stuff. Wheel speed is what kills them more than anything, and if you add a heavy tire like the TSLs I had on it, they don't last long.

FYI my buddy did a pretty cool mod on his D35. You need a spindle, rotor, hub, wheel bearings and outer shaft from a 95/96 full size Bronco. All of that bolts onto a D35 knuckle and you simply have some of the rotor machined off so that it's a smaller diameter, thus you can use your factory caliper and pads. You gain the MUCH stronger D44 lockout hub and the only real downside is that you have to use 5x5.5 wheels, and run adapters or redrill your bolt pattern on the rear to match the front. IMO it's way better than the mappyjack method, and light years ahead of a D44 knuckle swap.

 

[vonD1025]

Did tons of reading and figured out a lot but what’s going to be the best vehicle to grab the Dana 35 from and how bout the 8.8 what year explorer? Also the gear ratio for the front I want the 3.73 correct?