Jeep Wrangler Alloy USA Rear Axle Kit Dana 35 27-Spline Kit (1990-2002 YJ, TJ) Review

Jeep Wrangler Alloy USA Rear Axle Kit Dana 35 27-Spline Kit (1990-2002 YJ, TJ) Review


I’m Ryan from extremeterrain.com and this
is my review and installation of the Alloy USA rear axle shaft kit for your Dana 35 fitting
all 1990 to 2002 Wranglers. This is available in a factory 27-spline axle
shaft or an upgraded 30-spline axle shaft if you’re looking for something a little bit
stronger and have all of the supporting components. Today we’re gonna talk through the installation
of this axle shaft, which is going to be a pretty simple two out of three wrenches. There’s gonna be a little bit of disassembly
that you’ll need to get these installed, however, there’s no drilling, no major modification,
so again, two out of three wrenches and probably around two hours of time, maybe a little bit
more. But we’ll talk more about the installation
in just a second. We’re also gonna talk through the construction
and a few of the features of these axle shafts. These axle shafts are going to be significantly
stronger than factory, even if you go with the factory style 27-spline shaft. And for those of you who know the Dana 35
axle, know that it is a C-clip axle, and if you are to break an axle shaft when you’re
on the trail, that axle shaft, the broken part of it and the wheel and brake assembly
can all just completely come off the side of the jeep leaving you stranded on the trail. So, having an axle shaft that is going to
be plenty strong to hold up to the type of wheeling you’re gonna do and the size of tire
that you’re running is very, very important. They’ll give you the peace of mind to wheel
how you wanna wheel and keep you from having to do those tough trail repairs. Now, there are a couple other brands of axle
shafts out there that are going to be a similar 4140 chromoly material, they’re going to have
the same style lug pattern, gonna come with the same seals and the same bearings, just
being some different brands. So if you’re loyal to the Alloy USA brand,
I think they do make a good piece and the price difference isn’t going to be that significant
over some of the others. However, if you’re just interested in a chromoly
axle shaft, you are going to have a few to choose from. So, as I said, these are going to be a 4140
chromoly axle shafts, which means that they’re made of an alloy that is much stronger than
those factory axle shafts. They are going to be available in both a factory
style 27-spline axle shaft that’ll just slide into your factory style rear or a 30-spline
axle shaft that will require you to swap out a couple of other components inside of your
differential. However, having those additional splines is
going to give you some additional strength in the spline area of the shaft. These are going to be factory length so they’ll
fit right into your jeep. They come with pressed in wheel studs, they
are a five on four-and-a-half wheel pattern, which is going to be just like your factory,
and these do also come with your bearings and your seals so you’ll have everything you
need to install them. So, getting these installed on your jeep,
as I said before, is going to be a two-out-of-three-wrench job. There is a little bit of disassembly you’ll
need to do, however, there isn’t going to be any major cutting, drilling, grinding,
or modification of your jeep necessary, so it’s still going to be something a lot of
you can do in your driveway, given about two hours and some tools. The first step is going to be jacking up the
rear of the jeep, removing the tire, and taking your rear brakes apart. Then you’ll have to remove your differential
cover, of course, draining the fluid as you do so, and disassemble the rear differential
enough to be able to remove your C-clips and slide the axle shafts out. After that, you’ll replace your seals and
your bearings with the new ones that come in the kit, slide the axle shaft into place,
reinstall your C-clips and the rest of your differential, making sure that you get a good
seal on your differential cover before you refill it with fluid, and putting your brakes
back together to get you back on the road again. These axle shafts come in at right around
$330 for a pair of them and also the bearings and the seals, which I don’t think is a bad
price. There are other brands out there that are
going to be slightly more expensive, slightly less expensive, some of those are possibly
going to be a higher grade of chromoly that’s gonna be a little bit stronger, and some for
other years of jeeps will include additional components like ABS tone rings. However, for this year of jeep, for a replacement
chromoly axle shaft, I think these ones are appropriately priced, they’re gonna be strong,
and they’re gonna be an easy install. So, whether you’ve already broken a rear axle
shaft and you’re looking to upgrade or you’re upgrading because you’re putting big tires
on your jeep, you plan on wheeling hard and you don’t want the chance of breaking a shaft
on the trail, this is going to be a nice upgrade. So, that’s my review of the Alloy USA rear
axle kit fitting your Dana 35 in your 1990 to 2002 Wrangler that you can find right here
at extremeterrain.com.

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