Strengthen a D35

[dubbleJs]

What size tires are you running on your rig?

As for strength Id agree with all the forementioned parts that you can pick out amongst the jargon!....Truss, new shafts, and less skinny pedal!
 

[hps4evr]

aaron, i run the dana 35c in the rear of my YJ. its locked, 4.11 gears. and its been that way for 6 years of wheeling. i do understand that its a dana 35 so i dont drive it like its a dana 60. you've sen me wheel with my 33" tires. its lasted. i drive it every day to work and back. and yes, ive re-done gears and bearings on it this last spring. the axles are still good, and all parts are plenyful becasue everyone throws there old junk away. so maybe its the stealth rear-end nowadays:) anyways, there are a few truuss's otu there for them, and thats the week point. the housings bend. so if you've got the parts, and they were cheap, then by all means, you can go ahead and be the first person to ever swap a dana 35 into a jeep!!!
keep spareshafts on hand, and the tools to change them. maybe bring everything from the rearend. you drive a wagon, lots of room;)
i thought i saw Timken made a truss at one point.
good luck.

[NUXJR]

Aaron...check this out - http://www.4x4wire.com/jeep/reviews/super35truss/ 

[Bnine]

That truss has not been available for several years.

Superior does have another one that has either been just released, or will be shortly.

[NUXJR]

There is also this one - http://www.quadratec.com/products/16355_212.htm

[Bnine]

Thats a 4 link truss, which will work.

If you can weld that 4 link truss on, you might as well save 250$ and just cut 3 peices of square stock yourself and build essentailly the same thing. Minus the link brackets you dont need for an XJ.

[JackstandJohnny]

hey aaron, thought you might want to check this link out.  8.8 and a D30 for 600$ isn't great, but that 8.8 would swap right in, and the gears at 4;10 would be pretty decent with 33s.   and that is beefy.i LOVE the fact the YJ has the 8.8 out back. i can't wait to get on the gas when i get out wheeling and not have to say 'hm, D35.... better back off the skinny pedal'
haha, good luck with the swap. i also didn't break my D35 but i drove it like a wimp