The 35 and 8.25 are designations for rear axles used by Chrysler Corporation's Jeep Division. The Dana Spicer 35 is a lighter-duty axle, and the Chrysler-made 8.25-inch axle is designed for greater strength. The two axles have similar housings and it can be challenging to identify which axle is installed in your Jeep.
Dana Spicer 35 Axle
The Dana Spicer 35 has 26 splines. The ring gear in the Dana Spicer 35 is 7.562 inches and pinion gear diameter is 1.406 inches. The Dana Spicer 35 is 175 pounds. According to JP Magazine, "the ring gear, pinion, bearings, shafts, and housing are all light-duty parts."
Chrysler 8.25-inch Axle
Chrysler 8.25-inch axles produced between 1991 and 1996 have 27 splines. Beginning in mid-1996, it was built with 29 splines, making the axle stronger. The ring gear is 8.25 inches. Its pinion gear diameter is 1.626 inches.
The Chrysler 8.25-inch axle is slightly thicker and stronger than the Dana Spicer 35. Its housing, gears, tubes and carrier tend to hold up to stronger usage. The Chrysler axle uses larger bearings than the Dana Spicer 35. The Dana Spicer 35 design allows the axle to flex, causing some potential for breakage during hard use, or when using tires that are larger than the original equipment tires. JP Magazine states that on the Dana Spicer 35, the axle shafts are often the first component likely to fail. Aftermarket upgrades can be performed to increase the strength of the Dana Spicer 35 axle; one recommendation is to install an axle truss.
In most trucks, you can determine which axle is used by counting the bolts around the center cover and by observing the shape of the center cover. It is more difficult to differentiate between the Dana Spicer 35 and the Chrysler 8.25-inch axle because the two have the same number of bolts and are very similar in shape.
The Dana Spicer 35 has a "35C" marking on the housing. It has an oval-shaped 10-bolt cover which is slightly rounded on the bottom. It was originally installed in Jeep models including the 1984 to 1997 Wagoneer, 1984 to 1993 Cherokee, 1984 to 1996 Cherokee XJ and 1993-2000 Grand Cherokee. It was also original equipment on some Ford trucks.
The Chrysler 8.25-inch axle has an oval, 10-bolt cover. It was originally installed in Jeep models, including the 1991 and newer Cherokee XJ and 1996 and newer Cherokees.
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