Shop the Dana 35 Master Kit →
The Dana 35 has a bad reputation it only partly earns. On a stock Jeep it lasts a long time. Add taller tires, a locker and ledges, and the small ring gear and thin C-clip shafts fail first. The Dana 44 is the usual swap: bigger gear, thicker shafts, stronger housing.
Which Jeep Got Which Rear Axle
- Cherokee XJ, 1984-2001. Most got a Dana 35. Many, especially with the tow package, got a Chrysler 8.25 instead, and a few early trucks got a Dana 44.
- Wrangler TJ, 1997-2006. Dana 35 was standard. Some Sport and Sahara models were ordered with an optional Dana 44, and every 2003-2006 Rubicon got one with a factory locker.
- Wrangler JK, 2007-2018. Every JK has a Dana 44 rear, Rubicon or not. The Rubicon adds a selectable locker.
- Wrangler JL, 2018-on. Base Sport and Sahara models got the Dana 35 M200. Tow and gearing options moved many of them to the Dana 44 M220, and every Rubicon has the M220 with a locker.
Dana 35 vs Dana 44 Side by Side
| Spec | Dana 35 (XJ/TJ) | Dana 44 (TJ/JK) | JL M200 (Dana 35) | JL M220 (Dana 44) |
|---|---|---|---|---|
| Ring gear | About 7.56 in | About 8.5 in | 200 mm (about 7.9 in) | 220 mm (about 8.7 in) |
| Axle spline | 27 | 30 | 29 | 32 |
| Shaft diameter | About 1.18 in | About 1.31 in | About 1.24 in | About 1.41 in |
| Shaft retention | C-clip | C-clip | Bolt-in, no C-clip | Bolt-in, no C-clip |
| Cover bolts | 10 | 10 | Smaller cover | Larger cover |
| Safe tire size, hard use | About 31 in | About 35 in | About 33 in | About 35-37 in |
The shafts matter more than the ring gear. With a locker and one tire in the air, all the torque goes into one thin 27-spline shaft. The JL M200 is a real improvement, but still the smaller axle.
How to Identify Your Rear Axle
Do not count cover bolts. The XJ/TJ Dana 35 and the Dana 44 both use a 10-bolt cover, and so does a Ford 8.8. A Chrysler 8.25 has 12 bolts, which is an easy way to rule that one out on an XJ.
- The gear tag. A metal tag under one cover bolt usually lists the ratio and part number. They rust off, so do not count on it.
- Casting numbers. The model number is usually cast into the housing near the right side of the center section. Wire-brush it and look for 35 or 44.
- JL owners. Run the VIN or pull the window sticker and look for the rear axle line. A Rubicon is always M220.
When the Dana 35 Is Fine and When It Breaks Shafts
Keep the 35 if you run 31-inch tires or smaller, an open or limited-slip diff, and drive mostly on the street. A refresh with a Dana 35 rear master bearing kit ($212.99) gets it quiet again. Our Dana 35 problems and upgrade guide covers the usual failures.
The 35 breaks with 33-inch tires, a locker and someone hard on the throttle on a ledge. The shaft usually snaps just outboard of the C-clip and the outer half can slide out with the wheel still on it. That is why shops pair chromoly shafts with C-clip eliminators. The JL M200 does not have this problem because its shafts bolt in, but a locker on 35s can still twist its 29-spline shafts.
The TJ and JK 44s still use C-clips and do break shafts on 37s, but on 33s and 35s with a locker a healthy 44 keeps working. See our Dana 44 problems and rebuild cost guide.
Building Up the Dana 35
On an XJ or TJ, a traction upgrade on stock shafts means something like the Yukon Duragrip posi for the 27-spline Dana 35 ($807.50). Going all the way means the Yukon Ultimate 35 kit ($2,579.11), with 30-spline chromoly shafts, C-clip eliminators and a Grizzly locker. Gears are extra. A Dana 35 4.11 ring and pinion ($283.99) suits 31 to 33-inch tires.
On a JL, the M200 is worth building for 33s. The Yukon 4340 chromoly axle kit for the JL Dana 35 ($450.16) replaces the factory shafts. For gears, the Revolution JL Dana 35 rear 4.56 gear package ($1,014.99) comes complete, or pair a ring and pinion with the Revolution JL Dana 35 200mm master install kit ($318.99). For a full bearing job, there is the Yukon JL Dana 35 200mm master overhaul kit ($424.24). Add the Eaton ELocker for the JL Dana 35 M200 ($1,572.99) if you want a selectable locker. On rocks, the Yukon Hardcore nodular iron cover for the JL Dana 35 ($298.89) protects the ring gear from a dented cover.
Swapping to a Dana 44
For a TJ, a Dana 44 from a Rubicon or a factory-44 Sport is a direct bolt-in. Upgrade the shafts with Revolution Discovery Series chromoly TJ Dana 44 rear axles for disc brakes ($478.99). On a JL, a take-off M220 bolts to the same suspension mounts, but a Rubicon locker needs wiring before it works. Regear it with the Revolution JL Dana 44 rear 4.56 gear package ($1,065.99) or a ring and pinion plus the Revolution JL/JT Dana 44 rear master install kit ($338.99). The Yukon JL Dana 44 220mm rear master rebuild kit ($424.24) covers bearings on a used axle. For traction, the Eaton Truetrac for the Dana 44 M210/M220 ($856.99) is a good street choice. For crawling, the Eaton ELocker for the JL/JT Dana 44 M220 ($1,554.99) is a full selectable locker. On a JK, a Dana 44 JK rear master bearing kit ($260.99) handles the refresh.
Whichever way you go, front and rear ratios must match exactly. See picking a ratio after bigger tires and our backlash and pinion depth setup guide.
Build Up the 35 or Swap to a 44: What It Costs
| Path | DIY parts | Shop (rough) |
|---|---|---|
| Dana 35 bearing and seal refresh | About $215-$350 plus tools | About $700-$1,200 |
| XJ/TJ 35: gears plus Duragrip, stock shafts | About $1,100-$1,300 | About $1,800-$2,400 |
| XJ/TJ 35: Ultimate 35 kit plus gears | About $2,900-$3,200 | About $3,700-$4,500 |
| TJ: used Dana 44 swap plus gears | About $1,000-$2,000 | About $2,000-$3,500 |
| JL M200: gear package plus chromoly shafts | About $1,450-$1,550 | About $2,200-$2,900 |
| JL: used M220 swap plus gears | About $2,000-$4,000, used axle prices vary widely | About $3,000-$5,000 |
Once a Dana 35 build includes shafts, eliminators and a locker, you are paying 44 money for a 35. If you only need gears and mild traction, build the 35. If you are going to 35-inch tires, buy the 44 once. The differential fluid guide covers intervals, and our open vs limited slip vs locker guide helps pick the carrier.
More kits are in rebuild kits, gear oil in fluids, and setup gauges in tools. CoreTransmissionParts.com carries transmission and transfer case parts if the clunk is further up the driveline.
Refresh It or Build It Right
Stock tires and a noisy Dana 35? Do the bearings and seals in one pass. Going bigger? Start with the gears and shafts built for it.
Shop the Dana 35 Master Kit → JL Dana 44 Gear PackageFAQ
How can I tell a Dana 35 from a Dana 44 on my Jeep?
Both use a 10-bolt cover, so bolt count will not settle it. Look for the gear tag under a cover bolt, the model number cast into the housing, or the axle code on the build sheet. A Dana 44 center section and ring gear are visibly bigger, and on a JL the M220 cover is larger than the M200 cover.
Does every Jeep JK have a Dana 44 rear?
Yes. Every 2007-2018 JK, Rubicon or not, came with a Dana 44 rear with 30-spline C-clip shafts. The Rubicon added a selectable locker. The Dana 35 question only applies to XJ, TJ and JL owners.
What size tire is too big for a Dana 35?
A stock Dana 35 is fine on 31-inch tires for normal driving. At 33 inches it needs chromoly shafts, and with a locker and hard trail use it becomes the weak link. On 35s and up, most owners are better off swapping to a Dana 44.
Is it cheaper to build a Dana 35 or swap to a Dana 44?
If you only need gears and a limited slip, building the 35 is cheaper. Once you add shafts, C-clip eliminators and a locker, the parts bill often passes the cost of a used Dana 44 that already has a stronger ring gear and thicker shafts.