4 Wheel Drive/SUVs: Wrangler 1999, Sahara, wheel bolt pattern, 4 wheel parts wholesalers

Question
Carl,

I own a 1999 TJ Sahara, the d-35 in the rear failed, spider gears broke and that took a hunk out of the ring gear.  I can take it to one of 3 local Jeep dealers and have it fixed or I can purchase an entire d-44 rear off e-bay, there are a number of them. I don't go off road much but I would very much like to begin. The price of the d-44's are around $1,500, one has 20K miles with brakes and drums, the other is new but has no brake assembly.  So, if I do buy the new d-44 without brakes can I use the brake assembly from the d-35?  So any advice would be helpful.  Oh I guess I could also repair the differential myself, never did one but I'm somewhat mechanical.

Thanks
Bill

Answer
Bill,

If you plan on doing any hard core off roading, the dana-44 would be much better than the dana-35.  One of the problems with the 35, is that the axle tubes are quite thin, and prone to bending.  If you go with the 44, make sure that the wheel bolt pattern matches your stock pattern.  This should be 5 lug on a 4 1/2" pattern.  I would, also try to find one that has disk brakes.  I would recommend that you contact some of the custom suppliers, such as Currie Enterprises, and price some of their units.  The cost may be a little more, but they will build a rear end specifically for your TJ.

There are several other companies that sell heavy duty components for your dana-35, along with dana-44's, and Ford 9" rear ends.  I would suggest that you purchase a couple of off road magazines, such as 4-Wheeler, or JP, and check out their ads.  Another company that sells components, and publishes a free magazine called Off-Road Adventures is 4-Wheel Parts Wholesalers.

I would review these ads, and give some of the suppliers a phone call.  Most of them have technicians available, and they are, usually willing to discuss your needs.

  Carl