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Limited Slip from Jeep Cherokee into W123/W126 3.07? - Printable Version

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Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-27-2013

EDIT:I somehow managed to pull an idiot and give you a picture of a Ford 8.8 instead of a Dana 35. That is fixed now -- the pictured Jeep diff is most definitely a Dana 35 with limited slip.

Doing some research, I have found that the Jeep Cherokee with the 4.0 and a manual transmission came with a 3.07:1 gearset and, sometimes, limited slip. The limited slip clutches are apparently $60-70 and meant to be replaced every 60,000 miles. At least around here, the yards are plentiful with Jeep Cherokees, so the parts should be widely available, and that's a WHOLE lot cheaper than $1,000+ for the rare Mercedes clutches.

I'm intrigued as to whether I could swap one of the following between the Jeep and a 3.07 Mercedes differential:

1) The LSD components
2) The gears
3) The diff

The main issue I'd see with swapping the diff or gears is that they would have to fit the Mercedes structure. Apparently, the Jeep used 27-spline axle shafts between 1991 and 1996, which is what Mercedes used, so this might sync. I don't know what I'd do about the carrier (as far as which one I'd use, if either).

I'm going to keep an eye out for a Cherokee with 4.0 and 5-speed in the yards so that I can take the diff to bits and see if it looks swappable. Anyone have any thoughts on this?

Here's the Jeep:

[Image: 586073d1363393537-dana-35-lsd-forumrunne...192800.jpg]

Here's the 'Benz:

   

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - SurfRodder - 12-28-2013

interesting... I have owned several XJ's throughout the years. I currently have a couple of WJ (99-03ish Grand Cherokee) axle shafts (same axle as the XJ Cherokee, just longer halfs) sitting in my garage right now as well as a couple of M-B half shafts... I ill look at comparing them tomorrow and will post pics as long as I get off work early enough to feel like going out there and looking for shit.

That being said, 4.0s with manuals are not that common, I usually see 5 speeds beind the 2.5L 4 bangers and they have much taller gears.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-28-2013

(12-28-2013, 01:38 AM)SurfRodder interesting... I have owned several XJ's throughout the years. I currently have a couple of WJ (99-03ish Grand Cherokee) axle shafts (same axle as the XJ Cherokee, just longer halfs) sitting in my garage right now as well as a couple of M-B half shafts... I ill look at comparing them tomorrow and will post pics as long as I get off work early enough to feel like going out there and looking for shit.
Cool! If they're from a Grand Cherokee with the Dana 35, they should have the same spline count. If they're from a Dana 44, they should have a spline count of 30. It looks like the Dana 44 came with the V8s and the Dana 35 with the I6, which makes sense.
(12-28-2013, 01:38 AM)SurfRodder That being said, 4.0s with manuals are not that common, I usually see 5 speeds beind the 2.5L 4 bangers and they have much taller gears.
True. But they are common enough that I could go buy one from Craigslist tomorrow and have more than one to pick from, and certainly more common and cheaper that 6.9s and 560SECs.
Yeesh... I see your point. The closest yard with one of these cars is in PA. I guess I'll just keep looking.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - CRD4x4 - 12-28-2013

I don't know how helpful this is but my understanding is that all Jeep/Kaiser/AMC DJ5 Postal Jeeps (RHD RWD) came equipped with a Dana 44 LSD 3.08.
Perhaps this could be an alternative.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-28-2013

For the record, all Dana 35 diffs were 27-spline and they came in a multitude of ratios; so if this mod works, it wouldn't be limited to the 3.07.
(12-28-2013, 09:20 AM)CRD4x4 I don't know how helpful this is but my understanding is that all Jeep/Kaiser/AMC DJ5 Postal Jeeps (RHD RWD) came equipped with a Dana 44 LSD 3.08.
Perhaps this could be an alternative.

Interesting. Although I think that the Dana 44 was a 30-spline, that would still have the LSD goodies. Thanks for the tip.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-28-2013

OK, extrapolating from Car-Part.com, the Wrangler 4.0 5-speed also came with Dana 35 3.07. I might look for one in Jeep circles, since those guys seem to like playing with differentials.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-28-2013

(12-28-2013, 01:38 AM)SurfRodder interesting... I have owned several XJ's throughout the years. I currently have a couple of WJ (99-03ish Grand Cherokee) axle shafts (same axle as the XJ Cherokee, just longer halfs) sitting in my garage right now as well as a couple of M-B half shafts... I ill look at comparing them tomorrow and will post pics as long as I get off work early enough to feel like going out there and looking for ****.

That being said, 4.0s with manuals are not that common, I usually see 5 speeds beind the 2.5L 4 bangers and they have much taller gears.

D35 axle shaft diameter is 1.18". D44 is 1.31".

EDIT: 1.18" = 2.9972 cm, so basically 3 cm. This is good, as I'm willing to bet the 'Benz is metric.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - CRD4x4 - 12-28-2013

D35 axle shaft diameter is 1.18". D44 is 1.31".
[/quote]

How does this compare to Merc applications?

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-28-2013

(12-28-2013, 08:23 PM)CRD4x4 D35 axle shaft diameter is 1.18". D44 is 1.31".

How does this compare to Merc applications?
[/quote]

That's what I'm hoping SurfRodder can tell us.

Also, if the Mercedes and Jeep use the same tooth counts (likely), it might be possible to mash together a combination of the two gearsets to create one diff. For example, take the Jeep carrier and swap in the Mercedes gears that connect to the axles -- the little gears that are actually clutched.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - Jooseppi Luna - 12-28-2013

HOOO boy...

Looking at axle pictures online, it looks like the ratio between the size of the shaft and the size of the big can that's right before the shaft is 4<4.5:1. The size of the "can" on my 'SD is right about 12.7 cm... so that sets us up for a shaft diameter right around 3 cm.

This is looking more feasible.

I'm going to try find a Dana 35 in JY and see how the carrier plays with the '84 'TD they have in there. Sheesh, if the ring gear is interchangeable between the two without any more than minor drilling (which would resolve the issue of which pinion to use), any ratio Dana 35 would do.

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - SurfRodder - 12-29-2013

(12-28-2013, 08:33 PM)Jooseppi Luna
(12-28-2013, 08:23 PM)CRD4x4 D35 axle shaft diameter is 1.18". D44 is 1.31".
How does this compare to Merc applications?

That's what I'm hoping SurfRodder can tell us.
Looks like I have the D44 shafts (makes sense since I have the rare rear D44 in my XJ and thats where these shafts will end up if I ever get to swapping in these axles and the matching front steering & axle setup, likely be 2016 before I get to that) from a WJ GC... They measure 1.3" on my calipers.

I have been meaning to pull a couple of shafts from a junker to get dimensions (mainly length so I know how much to trim from the WJ shafts when the time comes. If I get around to that soon, Ill post up the other dimensions as well. That being said, if you found those numbers on pirate4x4 or a Jeep specific site, theyre likely correct.

(12-28-2013, 08:33 PM)Jooseppi Luna Also, if the Mercedes and Jeep use the same tooth counts (likely), it might be possible to mash together a combination of the two gearsets to create one diff. For example, take the Jeep carrier and swap in the Mercedes gears that connect to the axles -- the little gears that are actually clutched.
This actually seems promising as well. grabbing a junker setup and prooving the concept would be awesome because then you can buy all kinds of aftermarket lockers/lim. slips...very intriguing...

RE: Limited Slip from Jeep Cherokee into W123/W126 3.07? - raysorenson - 12-29-2013

List of things that have to work besides axle splines if the Heep carrier is used:

The O.D. of the carrier bearing outer races has to be the same as the Merc races, if they're larger you have to line bore the case precisely AND machine a new select fit snap ring groove AND find a new snap ring to fit that is available in various widths.

The distance between the carrier bearing outer races has to be the same or slightly less than the same measurement on the merc carrier or you can't use the select fit snap rings to set backlash.

The ring gear has to be centered by a step in the carrier. This step has to be so close to the inner diameter of the ring gear that it is typically a loose press fit. The bolts do not center the ring gear and should not be trusted to do so.

The ring gear seating surface has to be spaced, L to R, in the same place with both carriers. You may have around .04" or so to play with as far as snap rings to move the carrier L or R to get backlash right.

The assembled carrier, ring gear and bearing cones must slip in and out of the case with the pinion gear in place. If you've ever pulled a carrier out of a merc case, you know exactly what I'm talking about. The stock stuff barely fits and it takes a minute to figure out how to position the carrier into the correct (and only) position to remove it.

Not hatin' here, just making sure you know what you're up against.