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Specifications (Rear):
Chrysler 8.25" Rear Semi Float Axle
Overall Strength Rating: 3
Max. Tire Diameter Recommended: 33"
Ring Gear Size: 8.25"
(10) #3 Ring Gear Bolts on a 8" diam bolt circle
1.21" dia axle shaft with 29 splines
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Notes: This axle first appear in light 4x2 trucks in 1966 as was also used heavily in medium powered cars. It was the last solid rear axle used in Chrysler's rear drive cars built into 1989. It has seen extensive use in Dodge half-ton trucks (4x2 as well as 4x4) with 6 cylinder engines. There is much conflicting information as to when this axles was last used in full sized trucks. When the Dakota debuted in 1987, it was used for the V6 models and is still used today. It was also used extensively in the rear of Jeep Cherokee XJ's after 1997. Early units used the rather spindly 27 spline axle shafts, which were upgraded to 29 splines for 1996. A reasonably wide selection of lockers and LSD's are available. It's a c-clip unit.
Chrysler 9.25" Rear Semi Float Axle
Overall Strength Rating: 3+
Max. Tire Diameter Recommended: 35"
Ring Gear Size: 9.25"
(12) #7 Ring Gear Bolts
1.3" dia axle shaft with 31 splines
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Notes: This unit flrst appeared in the1969 era half ton trucks with V8's (small and big-block engines). If you think it looks like an enlarged 7.25-inch unit-that would be a fair assessment. It is even used in '70s muscle car applications and in the last of Chrysler's luxury tuna-boats into the early 1980s. This axle is unusual but cool and convenient in that it uses carrier bearings that are adjusted with hex adjusters reached through the axle tubes via a long tool. This can generally be considered to be a keeper in most half-ton applications, though the available lockers makes a fairly short list.
Specifications (Front):
Chrysler 7.625 IFS Front Axle
Model Years: 2000-2003
Overall Strength Rating: 2+
Max. Tire Diameter Recommended: 31"
Ring Gear Size: 7.625"
( #3 Ring Gear Bolts on a 8" diam bolt circle
1.12" dia axle shaft with 27 splines
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Notes: The aluminum cased unit is produced by Detroit Axle but is very similar to the Dana 35. Prior to the 2000 model year, either Dana or Chrysler produced units could be seen, but since the turn of the millennium, Chrysler has been trying to produce as much as possible in it's own Detroit Axle facility. The Chrysler and Dana units are effectively in the same strength and durability area.
'Dana 35 IFS Front Axle
Model Years: 1997-1999
Overall Strength Rating: 2
Max. Tire Diameter Recommended: 31"
Ring Gear Size: 7.56"
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Notes: The new era Dakota and Durango models often came with V-8's, and the Chrysler 7.25 IFS unit wasn't stout enough, so the Dana 35 IFS front is used. It has 27 spline axle shafts and CV assemblies. In the late '90's, it is found mixed with almost identical Chrysler built units. It's proven to be a decent performer in TTB or IFS form in the front of Fords and Dodges. In these units, it's merely a D35 ring, pinion and carrier in a new case and many of the solid axle's weak links are eliminated. The housing can easily be tweaked by spirited driving or simply difficult terrain in a combination with big tires. This will cause other failures, including broken axle shafts, blown differentials (or lockers) and failed axle bearings. The D35 is reliable in stock form with axle ratios as low as 4.10 combined with a 31x10.50 tires. With 35 inch tires, or larger, the axle is over- stressed and will break. Dana 35 upgrades start in two areas, a truss and beefier shafts. The improved shafts can be either units made of a better alloy steel or larger diameter shaft with a higher spline count, as with the Genuine Gear "Super" 35 kits. Next up is your choice of a locker or limited slip. With these modifications, you could be reasonably safe up to 35 inch tires and a 4.56 axle ratio. If you need more than that, swap to a Dana 44.
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