Deciding to upgrade the rear factory Dana 35 is an easy decision. I decided to go with a Ford 9 inch to replace the stock Dana 35 rear axle in my 1999 TJ.

I ordered a custom Ford 9 rear housing from Moser Engineering using stock TJ rear axle dimensions. I ordered the axle with a HD housing, Torino (big bearing) ends, tapered bearings, and 31 spline axle shafts. I ordered the shafts with a 5x4.5 bolt pattern to match the factory Dana 30 front.

Getting to work. Removing the stock Dana 35.







Bracket mock-up. Quick note here. I re-used the stock Dana 35 brackets. If you like sweat, blood, pain, tears and generally not enjoying life...then go the route I did. If not, just buy an axle bracket kit. The price tag may seem too steep, but it's not worth the hassle or time to properly remove and use the old brackets.





Here's the almost completed axle before paint, and one afterward with the brake lines and rear track-bar bracket installed.





Here is the completed axle, minus the 3rd member, ready for installation along with the new suspension parts. (Note: the lower fixed control arms were quickly replaced with adjustable RE arms before the first road test).



All mounted up.

I decided to use drum brakes with the 9" set-up. One of the reasons I decided on a Ford 9 is because I had experience building them from my CJ7. I ordered the axle housing knowing I was going to use Ford Econoline Van 11" drum brakes. I went to the junkyard and pulled off the backing plate from a donor van and used that year van to buy new brake shoes and brand new hardware from NAPA. To keep the stock, smaller, 5x4.5 bolt pattern, I ordered a set of Currie Enterprises' brand new 11" drums drilled with the 5x4.5 bolt pattern.

Dana 35 vs Ford 9" braking.



The 3rd member I used was stuffed with 4:11 gears and an ARB air-locker. Next is a series of photos showing the ARB and its associated parts installed into my TJ.