The Dana 35 is the weakest link in any built XJ. C-clip axle shafts, small 7.625" ring gear, and a reputation for breaking with 33"+ tires. The forum mantra: replace it.
The Dana 35 was the standard rear axle for most XJs (the 8.25 was optional on 1997-2001 and standard on certain trims). The D35 has a 7.625" ring gear, 27-spline C-clip axle shafts, and a reputation for being the weakest link in any built XJ.
Key weaknesses:
What the D35 CAN do:
Forum consensus on NAXJA, Cherokee Forum, and Pirate4x4: if you're building past 31s for any kind of real trail use, replace the Dana 35. The Ford 8.8 Explorer swap is the most common path; the Chrysler 8.25 swap is another. Trying to make a D35 reliable past 33s with chromoly shafts and a c-clip eliminator costs almost as much as an 8.8 swap and you still have a D35.
The Dana 35 has a few sub-variants — most common in XJ is the Model 35 with 27-spline. Pre-1991 some XJs had Dana 35 with 30-spline as an HD option.
Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.