(Dana 28 Above / Dana 35 Below)
Ford Bronco II’s came with a reverse cut Dana 28 TTB (Twin Traction Beam) 4WD front axle from 1984-1989. Bronco II’s built after 11/1989 came with the larger Dana 35 TTB. Unfortunately, most Bronco II’s you find will have a Dana 28 unless someone has swapped in the Dana 35.
Here are the axle specifications:
Specification | Dana 28 | Dana 35 |
Ring Gear Diameter | 6.625 Inches | 7.56 Inches |
Ring Gear Bolts | (8) 3/8″ x 24 RH | |
Pinion Stem | 1.312 Inch | 1.406 Inch |
Carrier Breaks | 3.73 & up, 3.45 & down | None (All D35 TTB gears use the “Hi-Ratio” (3.55 & up) carrier, regardless of ratio) |
Axle Shaft Diameter / Spline | 1.00 / 23 | 1.16″ / 27 |
Bolt Pattern | 12 Bolt Pattern On Front Of Axle | 10 Bolt Pattern On Front Of Axle |
Factory Ratios | 3.08, 3.45, 3.73, 4.10 | 3.27, 3.55, 3.73, 4.10 |
Aftermarket Ratios | 4.56, 5.13 (Discontinued) | 4.56, 4.88 5.13 |
U-Joints | 5-456x (1210 Series) | 5-297x (stock), 5-760x |
Max Tire Diameter Rating | 31 Inches | 35 Inches (TTB), 33 Inches (SLA IFS) |
Pinion Bearing Preload | 10 – 13 In Lbs (new) 6 – 8 In Lbs (used) | 15 – 25 In Lbs (new bearings) 6 – 8 In Lbs (used) |
Backlash | 0.005-0.008 Inches | 0.005-0.008 Inches |
Ring Gear Bolt Torque | 55 Lbs Foot | 70-90 Lbs Ft |
Carrier Bearing Cap Torque | 30-45 Lbs Foot | 47-67 Lbs Ft |
Pinion Nut Torque | 140 – 500 lbs-ft Foot (crush sleeve) | 170 – 500 lbs-ft (crush sleeve) |
Fluid | 2 Quarts Hypoid Gear Lubicant SAE 80W or 90W | 3 Quarts Hypoid Gear Lubicant SAE 80W or 90W |
Exploded Views & Part Numbers | Click HERE | Click HERE |
Resource – Randy’s Ring & Pinion |
The below photos show the visual differences between the Dana 28 and Dana 35.
Dana Axle Labels:
Your front axle may have a code stamped on the left carrier arm between the fill plug and axle end. It will look like ‘F17A’ or similar.
What this code represents is;
- E = 1980’s
- F = 1990’s
- 1 = Last digit of year
- 7 = Ranger
- A = Light Truck Engineering
Since the Dana 28’s were built in the 1980’s, their code will start with an ‘E’ where as the Dana 35’s were built in the 1990’s and will start with an ‘F’. The above mentioned code would indicate that the axle was a Ranger axle built in 1991.
There is a manufacturers label on the back side of the right axle beam that lists the year manufactured and gear ratio.
If you look at the top left of this sticker, you can see the Build of Materials number 610366 which identifies this as a:
610366 FORD 35 FRONT 1990 1/2-92 1/2 EXPLORER
The second box from top right identifies it as having 3.73 gears.
These stickers are on the back side of the passenger side axle beam. A chart of these numbers can be found below.
Axle Shaft Comparison:
Here is a picture of a Dana 28 & Dana 35 driver side axle shaft with the dimensions shown.
Spindle Comparisons:
Here’s a picture of a Dana 35 (Left) and Dana 28 (Right) spindle with dimensions shown.
Dana 35 Hybrid / Dana 35 Identification & Comparison:
The above photo shows a Dana 35 hybrid on the left that houses the Dana 28 carrier/gears. On the right you’ll see a true Dana 35 differential. The easiest way to check to see if your Dana 35, has Dana 28 “Guts”, is to pull the fill plug out from the front. If you can see the main cap, you have the Dana 28 guts (Sorry!). If you can see the end of the carrier, you have “The Real Thing”.
Note that the Dana 35 Hybrid has a smooth bottom
Ranger 4WD Front Axle ‘Build of Material’ Numbers:
610171 | FORD | DANA 28 | FRONT | 1983-1984 RANGER |
610223 | FORD | DANA 28 | FRONT | 1984 1/2-1985 RANGER/BRONCO II |
610249 | FORD | DANA 28 | FRONT | 1986-87 RANGER/BRONCO II |
610298 | FORD | DANA 28 | FRONT | 1987 1/2 RANGER/BRONCO II |
610300 | FORD | DANA 35 | FRONT | 1990 RANGER/BRONCO II |
610307 | FORD | DANA 28 | FRONT | 1988-1989 RANGER/BRONCO II |
610365 | FORD | DANA 35 | FRONT | 1990 1/2-92 1/2 RANGER/BRONCO II |
610366 | FORD | DANA 35 | FRONT | 1990 1/2-92 1/2 EXPLORER |
610410 | FORD | DANA 35 | FRONT | 1993-1994 1/2 EXPLORER ABS |
610418 | FORD | DANA 28 | FRONT | 1993-1994 1/2 RANGER (Hybrid axle) |
610419 | FORD | DANA 35 | FRONT | 1993-1994 1/2 RANGER |
610436 | FORD | DANA 35 | FRONT | 1992 1/2 RANGER |
610437 | FORD | DANA 35 | FRONT | 1992 1/2 EXPLORER |
610476 | FORD | DANA 35 | FRONT | 1995 EXPLORER – DISCONNECT (SLA IFS) |
610483 | FORD | DANA 35 | FRONT | 1995-1997 1/2 RANGER ABS |
610484 | FORD | DANA 28 | FRONT | 1995-1997 1/2 RANGER ABS (Hybrid axle) |
610556 | FORD | DANA 35 | FRONT | 1998 EXPLORER – NON DISCONNECT (SLA IFS) |
610581 | FORD | DANA 35 | FRONT | 1995-1996 EXPLORER – DISCONNECT (SLA IFS) |
610582 | FORD | DANA 35 | FRONT | 1995-1996 EXPLORER – DISCONNECT (SLA IFS) |
610585 | FORD | DANA 35 | FRONT | 1996 EXPLORER – NON DISCONNECT (SLA IFS) |
610586 | FORD | DANA 35 | FRONT | 1996 EXPLORER – NON DISCONNECT (SLA IFS) |
610642 | FORD | DANA 35 | FRONT | 1998-1998 1/2 EXPLORER – NON-DISCONNECT (SLA IFS) |
610643 | FORD | DANA 35 | FRONT | 1998-1998 1/2 EXPLORER – NON-DISCONNECT (SLA IFS) |
610644 | FORD | DANA 35 | FRONT | 1997 1/2 EXPLORER – NON-DISCONNECT (SLA IFS) |
610645 | FORD | DANA 35 | FRONT | 1998-1998 1/2 EXPLORER – NON-DISCONNECT (SLA IFS) |
610652 | FORD | DANA 35 | FRONT | 1997-1997 1/2 RANGER |
610653 | FORD | DANA 28 | FRONT | 1997 RANGER NON ABS (Hybrid Axle) |
610774 | FORD | DANA 35 | FRONT | 1999 EXPLORER – NON-DISCONNECT (SLA IFS) |
From the above, we can see BOM #s:
-
610418
-
610484
-
610653
Are the Dana 35 “hybrid” axles with the Dana 28 guts.
This number can be found at the top-left of the label located on the backside of the passenger side axle beam. For SLA axles, it will be on the passenger side axle tube
The Whole Front Assembly:
(Dana 28 front axle beams, radius arms, and crossmember)