Here you can see the completed...
Here you can see the completed rear disc-brake conversion installed. With this setup, we noticed immediate improvements in braking. The emergency brake could easily stall the engine if set while in gear, and our confidence in the rigs ability to "panic stop" is exactly where it should be with 35-inch tires. We like the fact that these kits were designed to work with the factory Jeep master cylinder and that they fit with 16-inch and larger wheels. We plan to run 16-inch wheels on this project.
Superior Axle also offers...
Superior Axle also offers a bolt-on truss kit for the Dana 35 rear axle. This product increases housing rigidity and strength by reducing the relational flex of axletubes and by limiting rotational forces, which eventually over time can break the rosette welds of the axlehousing. This part is completely bolt-on and features a durable black powdercoat finish. We like the fact that it mechanically ties together each part of the Dana 35, yet allows serviceability for gear swaps, oil changes, and differential troubleshooting. As you can see from this photo, all necessary mounting hardware is included.
The Super35 Axle Truss cradles...
The Super35 Axle Truss cradles each axletube with a three-dimensional boxed-plate section that triangulates each tube off a virtual intersectional plane, just behind the axlehousing. The system also triangulates the axle track-bar mount, providing additional strength. This system also benefits brake lines by protecting them from possible rock damage. The truss does not interfere with the factory gas tank at full compression of the rear suspension, and no special tools are necessary to install it.
Here you can see Dustin installing...
Here you can see Dustin installing the center portion of the truss kit. Basically this part consists of a factory stamped-steel differential cover with a section of boxed plated welded to it. Plates with captured nuts allow the center section to bolt to the axle portion of the truss. One wrench is all you need to bolt the three parts together. Once installed this further increases strength of the truss by distributing forces over the entire mounting flange of the differential cover.
The truss system requires...
The truss system requires relocation of the factory lower shock mounts. This slight change in mounting location should in theory accommodate improved suspension flex because the new location is lower than before, allowing a slightly longer shock to be used if desired. This bracket provides further rigidity to the truss by triangulating it to a point lower than the axletubes. As far as we see it, housing strength is no longer an issue with the Super 35 Truss installed.
This is the complete axle...
This is the complete axle truss installed on our donor Dana 35 axlehousing. Detail-oriented readers may notice a small differential skidplate protecting the lower section of the differential cover. We added this because we thought the factory cover might leave an opportunity for rock damage. Rugged Ridge supplied us with one of its bolt-on Dana 35 differential skidplates designed to go on over the lower portion of the factory cover. We had to modify it slightly to fit with the Super 35 Truss installed. This modification didn't compromise the strength of the skid or mounting footprint. This part gave us peace of mind that the thin stamped sheetmetal differential cover wouldn't be damaged on the trail.
A Better Shaft
Tom Wood provided a stout CV rear driveshaft featuring his 1330 Gold Seal U-joints and 2-inch tube. We like Tom's shafts because he uses thick-wall tubing and his U-joints feature a warranty that covers the shaft as well. In other words, if a Gold Seal universal joint should fail, Tom Wood's Custom Drive Shafts will also fix damage to the driveshaft.
Eliminate the C-clips!
As of press time, Superior Axle had another trick axle upgrade for TJ owners with Dana 35 C-clip rear ends. This C- kit eliminates the dreaded C-clip axles and allows the customer a much more reliable axle retaining method. Never again will you have to worry about the dreaded scenario of breaking a C-clip axle on the trail. The shafts are made from the same high-strength chromoly alloy we showed you at the start of this story, and the whole kit bolts in with no cutting or welding. These kits include 30-spline dual-lug pattern axleshafts and retail for right around $600. We plan to upgrade to this kit in the near future.