Dana 8.25

[Luciana]

Chrysler8.25 OX Lockers are designed for gear ratios of 2.73 and numerically higher, and factory spline counts of 27 and 29. Differentials from 1997 and on will be 29 spline, please ensure correct spline count when ordering.

The Chrysler 8.25" uses c-clips to hold the axle shafts into the differential side gears. Limited clearance between the axle shaft c-clip grooves and side gears can make c-clip installation and removal difficult. When c-clip installation is difficult, selecting thinner c-clips should allow easier future removal. ARB Air Lockers actually come with multiple c-clip thicknesses from which the installer can choose.

Removal of the c-clips is greatly eased by removing the spider gear pinion shaft. Rotate the carrier until the pinion shaft pin is exposed and remove the pin, pinion shaft, and small spider gears. The axle shafts can now be pushed in further to allow the c-clips to fall out with little effort. Re-install everything in the reverse order, being sure to retain the thrust washers on all four spider gears. Loctite is used on the pinion shaft pin from factory and should also be used during re-assembly.

Superior also manufactured 30-7/8" 29-spline c-clip axle shafts, for the Jeep Liberty's Chrysler 8.25" rear axle. They were made of 4340 chromoly steel and were advertised to be 35% stronger than OEM shafts (Superior Gear is no longer in business).

The Ruff Stuff Specialties Chrysler 8.25" .375 One Piece Diff Cover is currently the only fabricated cover constructed of 3/8" plate steel with a 1/2" plate steel ring. It features a 1" fill plug. Many companies make 1/4" covers but Ruffstuff is the only company known for a 3/8" thick cover. This cover is welded inside and out and then machined flat.

The PML 8.25" Differential Cover is constructed of aluminum, features both a threaded fill plug and a threaded drain plug, and holds 3/4 quart more oil than stock. The cover also comes with heatsinking fins, but they must be ground off if the cover's to be used in conjunction with a fuel tank skid plate.

The gear lube in the Chrysler 8.25" should be changed every 12,000 miles. Off-roading and towing subjects the differential to increased torque, dirt, and water. If the Liberty isn't off-roaded, isn't used for towing, and follows the Schedule A maintenance plan, it may be possible to stretch this interval. The differential housing requires 4.4 pints (2.08 liters) of lube and, if a limited slip is present, 4 ounces (118 milliliters) of limited slip additive. Aftermarket differential covers will change the required lube volume. 75W-90 dino lube should be used for light duty applications and 75W-140 synthetic for heavy duty off-roading and towing.

This is my first post on the Comanche Club forum. I have a d35 rear axle that is leaking and has bent shafts. I want to swap out the d35 for a Chrysler 8.25 out of a 97+ xj. I know it will need new perches welded on. What other modification will need to be done? Will this be an easy swap? Any info regarding brakes and fit would be helpful. My Comanche is an 87 4x4 with a 3.55 gear ratio. It also has a 2.5 inch lift. I would really appreciate your help. Thanks! -joe

I elongated the stock shock mount holes to fit a larger diameter axle tube. worked ok. :thumbsup: new perches would be better. pay attention to the orientation of the shock lower mounts as they are different than XJs.

It does. I had my driveshaft made up when I did my 4wd swap years ago. At that time, I kept with the dana 35 and I had a couple inches of lift. Since then, I've swapped to an 8.25 and about another inch and a half of lift due to my Metric Ton springs. The driveshaft was a little short for comfort after the springs, but after the different axle went in the shaft was just about right.

Clean off all of the mounts before anything else. I want to say that there would be clearance issues with the u-bolts otherwise. Also, if you're going as far as an axle swap, might as well add some dana 35 Grand Cherokee disk brakes too. Easy enough to do... just enlarge the center hole a but and everything just bolts in place.

... and don't be silly with yourself like I did. If you're going spring under or over, just add the spring perches that you need. Hauling around extra steel that'll never get used... all I'm doin now... why would I think that was a good idea anyhow?... should've just left it alone... I digress...

IIRC barnes4wd.com is cheaper then ruff stuff and just grab the spring plates from the xj the axle came out of. ubolts are a toss up. most are around the same price. i got some from autozone because i needed them that day.

I cannot get ubolts locally without waiting.....I have got lucky in the past and have bought them from the autoparts store for 22-25 apiece. Its nice to have a turn key setup. Ruff Stuff is high quality parts. Discount is nice too...search for discount codes..

I have not tried to hook the DS up yet....if its too short, ill just have the stock shaft shortened but that entails driving 70 miles one way so I hope it just works. After the small suspension lift I have my fingers crossed.

My local junk yard is having a 50% off sale this weekend, are there any differences other than the spline count and brake set up on the chrysler 8.25 rear that I should be aware of? is the "flat bottom" the only way to identify these diffs? thanks.

The '03-'07 Liberty KJ version ( the '02 had standard rear drums) would be a score. I am not sure about the '08 and up KK versions. The KJ may have a few more brackets to remove but that wouldn't be hard

The Dana 35 had 1.18" shafts and 27 splines. The early 8.25 axles had 1.17" shafts and 27 splines. The ring gear is larger than the Dana 35, but that's not where most Dana 35s fail. If you go strictly by shaft diameter and spline count, the Dana 35 should be stronger than the early 8.25.

The KJ is virtually the same at 60" wms-wms. The JK is a completely different jeep and never used the 8.25. The difference between the KJ & late XJ 8.25 is the suspension mounts and they have to be removed anyway. The axle in the KK was the "corporate 210mm." While I believe that this is a new designation for the corporate 8.25 I have not confirmed that or whether there are internal differences

Your link is for a guy who did a solid front axle swap with a custom Dana 60 rear axle to match his custom Dana 60 front axle neither of which is in any way stock. When making such a heavily modified rig you can spec your axles pretty much how you want. This would be about like swapping full-sized Ford axles under an MJ and then saying that all MJ axles are 67.5" wide because they are 67.5" under that MJ. The KJ 8.25 is 60". It has also been swapped into numerous XJ's as an alternative disc-brake equipped upgrade for the D35. The numbers you find on the 'net may change very slightly due mainly to people not using the same thing as the "wheel mounting surface" but not by 5". The JK is 65" and is noticeably wider than a KJ's axle. The track width of the front of a Liberty is about 62" at ride height. As it is IFS that measurement actually can change as the suspension cycles where it will not for a solid axle.

The ARB Chrysler 8.25" air locker RD93 for your 29 spline axle for all gear ratios, can instantly lock differentials and allow you to tackle the toughest off-road terrain. The world's best traction aid, ARB Air Lockers keep you moving in all conditions.

Air Lockers from ARB are currently available in over 100 configurations to suit a wide range of off-road and 4x4 vehicles from around the world. Because the Chrysler 8.25" ARB #RD93 air locker is only engaged when needed, it can be installed in BOTH the front and rear axles, with separate switches independently controlling the RD93 air locker from within the off-road truck or vehicle.

Installation of the ARB RD93 air locker should be performed by a qualified differential technician, although no special tools or skills are required apart from those necessary for fitting a standard differential. When installed with an ARB air compressor (high output or mini), the ARB #RD93 - Chrysler 8.25" locker system is supplied as a complete kit which contains all of the parts necessary for proper installation, including industrial grade control switches, air lines and fittings. ARB offers two compressor models suitable for RD93 air locker operation (high output air compressor or mini air compressor). A dedicated air activation system is available which is extremely durable and compact. Alternatively a larger compressor can be specified, which is also perfect for inflating tires, air mattresses and a host of other applications where compressed air is required.

The XJ 8.25 axles were either 27 or 29spl depending on the year. Those had larger axle tubes, so were considered almost equal in strength to a D44, trading the gears and shafts vs the build strength of the 8.25. A D44 is still stronger and more desirable though.

I'm not really familiar with the Commander specs, but it should have 29spline shafts, 3" axle tubes and the possibility of a factory e-locker or limited slip, in addition to being set up for control arms.

2020 Gladiator Mojave - 33" Falken mud tires, LoD side steps, Zroadz bed rack, Quadratec QRC winch bumper, Superwinch EPi 9.0, Kleinn on-board air, Kleinn air horns, lots of lights, Yaesu ham radio with GPS tracker.

More splines is stronger, so 29 is good. A D44 or 8.8 are always better to build on for the aftermarket support, of course the 8.8 is a little narrow for a TJ, but we've dealt with it since it's often easier to find than a proper-width used D44. Sadly, I don't know if the 8.25" brackets are in the proper locations for a TJ, probably not...

The differential cover is a 1 piece 3/8" (.375") plate steel cap bent 8 ways then welded to a 1/2" ring to better match up with the newer lockers. The fill plug is a generous 1.0" ID for easy fill and oil level check. This is a fully welded Chrysler 8.25" Differential Cover, welded inside and out with fill plug.

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