What is the biggest tire you would run on a dana 27?

I broke a 27 carrier etc. with 31s. V6, rocky dirt.

Depends a lot on vehicle power, weight, and terrain. For example : A dana 60 holds up pretty good in the front of my blazer with a V8, auto, locker, and 38" tires. My 7,000# Cummins Dodge with a manual, locker and 38"s breaks them like twigs in the rocks but they hold up OK in the dirt is I'm careful. Going to bigger shafts and a powrlock vs. detroit.

I'm going to a D30 in my Jeep and will run up to 33s on it, 31s for now, prefer a posi but getting a Lockright in the deal so we will see. The 27 doesn't seem worth messing with for offroad when you look at the strength, drum brakes, and poor steering angle.

 

Definitely do the stud swap on the steering knuckle if you continue to run the 27.....I've had one side strip out on the trail, forced me to do the stud swap to get home. Also try and find the passenger knuckle with the double holes for steering linkage and tie rod. This improves the steering and handling on the road.