- Joined
- March 4, 2007
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- 26,320
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- City, State
- anaheim hills,california
- Year, Model & Trim Level
- 95 ranger 4x4/ 91 X 4x4
...For anyone with a Ranger that has a Hybrid Dana 35 and wanted to do a True Dana 35 swap, and to those who wanted to know the difference, this threads for you...
...Be sure to check out this thread on the C-clip Eliminator before doing this swap...
http://www.explorerforum.com/forums/showthread.php?t=256302
...A huge Thanks to 90Ranajo and his current build, as if it were not for him, this project may never of happened...http://www.explorerforum.com/forums/showthread.php?t=245312
__________________________________________________________________________________________________
Note A:..This is a what a True Dana 35 looks like inside...All the pictures below noted as "True Dana 35" are shown with an ARB locker installed...
...Note B:..On this swap I chose to keep my existing beams and just do the pumpkin swap......To some, it may be easier to swap a complete true Dana 35 in but, I wanted to know all of the in's and outs of my "Hybrid", to a true, Dana 35 swap...
____________________________________________________________________________________________
Dana 28 vehicles...
Dana 28 was used on Ranger/BII's up to and thru 1990...This is a transition year so you will need to check the vehicle...
Explorer and Navajo Owners...
All 91-94 Explorer and Navajo's have a true Dana 35 so you will not need to worry if it has a Dana 28 or a Hybrid Dana 35...
Donor vehicles for swapping in a True Dana 35 are as follows..
90-97 Ranger
90 BII (only)
91-94 Explorer
91-94 Navajo
Side Note:
It is common for the vehicles that have the Hybrid Dana 35 to also have a 7.5 rear axle while the vehicles with the true Dana 35 will have the 8.8 rear axle
What years had the "Hybrid"
...The "Hybrid" Dana 35 can only be found on 93-97 Rangers with 2.3L and some 3.0L engines and they usually had 3.73 or 4.10 gears...The "Hybrid" can also be found on 90 - 97 Ford Aerostar AWD's...The hybrid is a considerable upgrade from the old Dana 28, as that from the first U joint out of the pumpkin, it is all Dana 35.
Identification
On a "Hybrid", if you pull the fill plug you will see a bearing cap. On the "True" Dana 35 you will see the carrier.
"Hybrid" on the left, true Dana 35 on the right..
...The easiest way to tell if you have a "Hybrid" Dana 35 is by looking at the bottom of the front pumpkin and you can do this by just looking under the Ranger...The "Hybrid" has a smooth pumpkin while the true Dana 35 is ribbed for strength...
Dana 35 on left, "Hybrid" on right...
Rough pumpkin measurements
...Measuring the front spacing of the true Dana 35...
...Measuring the front spacing of the "Hybrid"...
...Double checking the fit to the "hybrid" drivers side axle arm for the gears to fit, and they do...
..You can see in these first two pics that the "Hybrid" pumpkin is about 1 1/2" shorter than the true Dana 35 pumpkin...This is why the "Hybrid" front drive shaft is longer and needs to be shortened or replaced after the pumpkin swap...
Dana 35...approx. 10 3/4"...
"Hybrid"...approx. 9 1/4"...
Dana 35...
"Hybrid"...
Front Driveshaft
...The Hybrid drive shaft is about 1 1/2" plus longer. You will need to either shorten the driveshaft or, just swap in one from a true Dana 35 vehicle...If you don't, you run the risk of at least, cracking your transfer case housing...
__________________________________________________________________________________________________
Sticking with the Hybrid Dana 35???...:scratch:
Gears
...For those who already have a hybrid Dana 35 and you want to replace your gears with new gears, you must re-gear with a gear set made specifically for the "Hybrid"...You can not use regular Dana 28 gears...The pinion in a hybrid has a longer shank...Your best bet would be to pull them from a junkyard...
Shafts
...For the "Hybrid" Dana 35 shafts that go into the pumpkin, good luck finding them...This is the common failure point on a "Hybrid"...
The "Hybrid" Drive Shaft...
...We did find out, if you pushed a Dana 35 1"+ forward or lifted it higher and needed a longer drive shaft or, you have a solid axle that is moved forward by 1"- 1-1/2", the drive shaft off the Hybrid is perfect for this, as it is longer and a direct replacement...
..:scratch:...And where did the Hybrid front driveshaft wind up finding a home you might ask???...Post #56...
http://www.explorerforum.com/forums/showthread.php?t=246245&page=3
...Be sure to check out this thread on the C-clip Eliminator before doing this swap...
http://www.explorerforum.com/forums/showthread.php?t=256302
...A huge Thanks to 90Ranajo and his current build, as if it were not for him, this project may never of happened...http://www.explorerforum.com/forums/showthread.php?t=245312
__________________________________________________________________________________________________
Note A:..This is a what a True Dana 35 looks like inside...All the pictures below noted as "True Dana 35" are shown with an ARB locker installed...
...Note B:..On this swap I chose to keep my existing beams and just do the pumpkin swap......To some, it may be easier to swap a complete true Dana 35 in but, I wanted to know all of the in's and outs of my "Hybrid", to a true, Dana 35 swap...
____________________________________________________________________________________________
Dana 28 vehicles...
Dana 28 was used on Ranger/BII's up to and thru 1990...This is a transition year so you will need to check the vehicle...
Explorer and Navajo Owners...
All 91-94 Explorer and Navajo's have a true Dana 35 so you will not need to worry if it has a Dana 28 or a Hybrid Dana 35...
Donor vehicles for swapping in a True Dana 35 are as follows..
90-97 Ranger
90 BII (only)
91-94 Explorer
91-94 Navajo
Side Note:
It is common for the vehicles that have the Hybrid Dana 35 to also have a 7.5 rear axle while the vehicles with the true Dana 35 will have the 8.8 rear axle
What years had the "Hybrid"
...The "Hybrid" Dana 35 can only be found on 93-97 Rangers with 2.3L and some 3.0L engines and they usually had 3.73 or 4.10 gears...The "Hybrid" can also be found on 90 - 97 Ford Aerostar AWD's...The hybrid is a considerable upgrade from the old Dana 28, as that from the first U joint out of the pumpkin, it is all Dana 35.
Identification
On a "Hybrid", if you pull the fill plug you will see a bearing cap. On the "True" Dana 35 you will see the carrier.
"Hybrid" on the left, true Dana 35 on the right..
...The easiest way to tell if you have a "Hybrid" Dana 35 is by looking at the bottom of the front pumpkin and you can do this by just looking under the Ranger...The "Hybrid" has a smooth pumpkin while the true Dana 35 is ribbed for strength...
Dana 35 on left, "Hybrid" on right...
Rough pumpkin measurements
...Measuring the front spacing of the true Dana 35...
...Measuring the front spacing of the "Hybrid"...
...Double checking the fit to the "hybrid" drivers side axle arm for the gears to fit, and they do...
..You can see in these first two pics that the "Hybrid" pumpkin is about 1 1/2" shorter than the true Dana 35 pumpkin...This is why the "Hybrid" front drive shaft is longer and needs to be shortened or replaced after the pumpkin swap...
Dana 35...approx. 10 3/4"...
"Hybrid"...approx. 9 1/4"...
Dana 35...
"Hybrid"...
Front Driveshaft
...The Hybrid drive shaft is about 1 1/2" plus longer. You will need to either shorten the driveshaft or, just swap in one from a true Dana 35 vehicle...If you don't, you run the risk of at least, cracking your transfer case housing...
__________________________________________________________________________________________________
Sticking with the Hybrid Dana 35???...:scratch:
Gears
...For those who already have a hybrid Dana 35 and you want to replace your gears with new gears, you must re-gear with a gear set made specifically for the "Hybrid"...You can not use regular Dana 28 gears...The pinion in a hybrid has a longer shank...Your best bet would be to pull them from a junkyard...
Shafts
...For the "Hybrid" Dana 35 shafts that go into the pumpkin, good luck finding them...This is the common failure point on a "Hybrid"...
The "Hybrid" Drive Shaft...
...We did find out, if you pushed a Dana 35 1"+ forward or lifted it higher and needed a longer drive shaft or, you have a solid axle that is moved forward by 1"- 1-1/2", the drive shaft off the Hybrid is perfect for this, as it is longer and a direct replacement...
..:scratch:...And where did the Hybrid front driveshaft wind up finding a home you might ask???...Post #56...
http://www.explorerforum.com/forums/showthread.php?t=246245&page=3