How To Re-Gear a Dana 44

This video shows how to re-gear your Dana 44 axle. The same method can be applied to many axle types such as a Dana 30.
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Last updated: May 11, 2023

[@jkleo4846]

best vid I've ever seen on setting up gears and the ARB. thanks for this, brother!

[@TheBFHGarage]

Thanks! I appreciate the compliment. I'll be adding more gearing videos in the future so stay tuned and subscribe if you haven't already.

[@snicks50]

if you say so lol

[@stephenbaldwin5674]

Wish you were closer to Oklahoma- I’d be throwing some $ your way to install mine!

[@DiCimatti]

I wanted to take a moment to express my most sincere gratitude for putting this video up on youtube. I had to take my axle apart to replace a bent housing and could not have done it without this extremely detailed video. My rig is back on the road again, in part, thanks to you! 🙏

[@TheBFHGarage]

That's awesome to hear! Glad it helped out!

[@Okie-Tom]

It is refreshing to watch someone that cares enough about their work to do it correctly! Bravo Sir!

[@chuckkie9159]

Yes... as a mechanical engineer, I say your differential install is excellently done perfectly the way it should be. Great job. Hats off. And your barber does a great job too. 😊

[@TheBFHGarage]

😂🤣

[@CallaFab]

After watching this, I'm not sure I trust a shop to do it right! Best video I've seen on regearing.

[@TheBFHGarage]

Thanks for the compliment!

[@davidcooper6618]

Great Video from someone who has experience and common sense. Good demostration of how not to overcomplicate things. Thank you!

[@OnPointDroneWorks]

Woo Hoo, Your videos are awesome I just came back to watch this one one last time as I get ready for final assembly. You took all the mystery out of making this overwhelming job manageable. Thanks

[@5400bowen]

I don’t remember anyone else pressing the bearing on using the cup and having the pinion upside down so you don’t need the perfect size piece of pipe. So you can just cut the old bearing off and slit the inner race and then you have the perfect tool to do the pressing. Another great technique like so many in this video.

[@TRAINHD77]

Best informative step by step video on ARB Ring and Pinion setup on KZbin!!!!

[@yellowjacket548]

Definitely an excellent video! I've done several of my 8.5" Chevy's and one of my 9". My Dana 44's are next on my TJ, and they will be my first 44s. Thanks for taking the time to make this video.

[@tjlqk3]

So many great toss in this videos that the 'pros' never mentioned. Great video

[@TheBFHGarage]

Because they want your business!

[@setnbronco4932]

good info on using new bearings for setups, I learned that lesson after I used a set of old bearings for setups, got everything dialed in with the setups, changed to the new bearings and damn it was off, live and learn

[@jasoncox5674]

I was today years old when I learned you can do 3.92s in a dana 44 without changing the carrier (thick cut gears). Found your video, now I'm ready! Great video!

[@danielhh64]

Thanks a lot for shearing your experience and knowledge. This video helps me much and i reach a great result. Here in Brazil i didn't find a content as useful like this.

[@TheBFHGarage]

Glad it helped you out!

[@TRUC52]

Appreciate you Sir for your time and talent in making this video! Loved the knowledge AND the tips especially 👍

[@Brakemann1]

Great video. I’ve watched it three different times and confident that I’ll be able to re-gear my Gladiator. Thank you.

[@TheBFHGarage]

Your Gladiator will be just slightly different as you'll have to take apart the FAD as well. I have a JL on my calendar to get done soon and will make a video on it.

[@znuh]

Thank you for this! Very thorough and clear, your tip with the wrench to remove the carrier is genius!

[@KingRandyP]

Great video Bro! Don't know where I'd be without it.

[@fernandocabral275]

Great video. Thanks for sharing your knowledge

[@maz3588]

That is an absolutely brilliant video. Very clear content. Well done...

[@garymort5561]

Great video . I am about to regear a Dana 60 in a 55 Chev . Its an Ex drag car with a 4 link ( that i imported from USA to covid free New Zealand ....so after wstching your video i am going to have a go at leaving the housing in place . Thanks for you time making this mate

[@InexplicableBill]

That was awesome man. Thanks for the time you put into this!

[@TheBFHGarage]

Thanks! Be sure to check out my other videos on re-gearing 👍

[@88HillTop]

Yo, this video is a clean, methodical, by the numbers setup for this locker. Keep doing what you’re doing bro!

[@TheBFHGarage]

Thanks for the compliment!

[@Bore_Punch]

First time in and with a nice pattern. Thanks for tips. Especially the one for removing carrier with the wrench

[@TheBFHGarage]

Thanks, you're welcome!

[@darinsullaphen4683]

a great and thorough teacher; Thanks for a great video

[@TheBFHGarage]

Thank you for the complement!

[@ammarazez7230]

Thank you that was really helpful and informative, you are the real youtuber!

[@RobKingRC]

Nice video Bud, i love installing gears!!!

[@rhoadizzle]

Have to do a dana 80 sunday and I'm way more confident after watching this. Lots of things here that a manual doesn't show. Thanks a ton!

[@TheBFHGarage]

I'll be adding more re-gear videos in the future.

[@rhoadizzle]

@@TheBFHGarage Subscribed! Got mine all apart and found a giant washer (1/8" thick, 3.5" OD, 2" ID) in pieces and laying in the pocket of oil under the pinion shaft. Trying to make heads or tails of where it came from...it's not a giant factory shim is it? I'd hate to see the amount of pinion shim kits I'd have to buy to restack in place of that monster!

[@TheBFHGarage]

@@rhoadizzle It could be. Take a few pics of your washer pieces and of the inside of your pumpkin and send them to [e-mail] and I'll take a look when I have time.

[@tork62077]

Great video thanks for sharing.

[@robertleese5039]

Dam this is a really good video. I needed this video

[@jerseyjeeper1575]

Nice job and video. Thanks!

[@TheBFHGarage]

Glad you liked it!

[@rhettguillory45]

Very informative!

[@frankcaccamo3568]

Ace video simply the best video bro

[@jworthe]

Great video!

[@rl8750]

Thanks, learned allot.

[@DumbCarGuy]

Gotta LOVE those big old shower towels.

[@mydogsnameisbob]

Hey, I'm up in Longmont. I'm getting the things together to do 4.88's on my 16 Rubicon. Just wanted to say thanks for putting the info out there, it's much appreciated. I've always wanted to set up a diff, I'm looking forward to doing it in the fall.

[@TheBFHGarage]

Don't fear the re-gear! Do research a lot though 😁

[@johnr5545]

Nice job

[@Imustfly]

25 people gave this a thumbs DOWN? JFC,...it was an excellent video. Excuse the back of his head on occasion, but it was necessary for the camera angle on his one man show !! Excellent video, sir !!

[@TheBFHGarage]

I've watched a lot of excellent videos on youtube and they all have thumbs down. No biggie as long as it helps the intended users!

[@vids595]

Ive done two Sana 35C (with the clipped axle shafts, one Dana 30, and a Dana 44a. Now I need to do the Dana 44 in my 1988 jeep Comanche. Its long enough in between that I have to watch a bunch of videos each time. This seem like the best video Ive ever seen, it has all the tricks and tips.

[@genecenora7176]

Hello from Pittsburgh pa.

[@darinchamberlain7304]

Wow! nice video man!! Exactly how I do everything....but never film it...

[@manuelsolano7525]

Great video Thank you.

[@TheBFHGarage]

Are you in Denver area?

[@manuelsolano7525]

@@TheBFHGarage I'm in new jersey your video is going to help me whit my dana 30 thank you.

[@TheBFHGarage]

@@manuelsolano7525 My wife's last name is Solano and she had a cousin named Manuel 👍. Check out my build series, I re-gear a Dana 30.

[@manuelsolano7525]

@@TheBFHGarage I was born in the Dominican Republic and came here as a child. it maybe possible that we are related ?

[@TheBFHGarage]

@@manuelsolano7525 in this world, who knows! 🤪🤣😂

[@piotrwaalk705]

Luz na przekładni sprawdza się w 4 miejscach na okręgu,wiadomo to robi maszyna ale warto sprawdzić,tak samo jak się kręci przekładnia na 360⁰. Co do przykręcania zębatki to brawo na 2 razy, ale ja zastosowałbym klej do gwintów (średnia moc, też dałbym klej na podkowach które trzymają przekładnię). Warto też przed każdym montażem takich śrub sprawdzić gwinty na śrubach i gwint wewnętrzny . Nie każdy stosuje olej lub smar(miedź lub grafitowy) pod podkładki lub pod łeb śruby aby moment dociagania był jednakowy na wszystkich śrubach. Przy zwykłych śrubach lub płytkich gwintach należy uważać bo smar zwiększa docisk po przez redukcję tarcia pod podkładką i łbem śruby. Gratulacje nie każdy sprawdza ułożenie wałka atakującego ,A zakres rozkładania się zębów wałka atakującego warto sprawdzić na całym zakresie dużej zębatki. Bo przekładnia z zębami skośnymi jest bardziej wrażliwa na zbyt ciasne spasowanie jak i na za duży luz.. A dlatego myślałem o kleju do gwintów bo przy terenowych autach gdzie jest redukcja,duże koła nacisk na przekładnie jest naprawdę duży. Warto nawet skontrolować przekładnie planetarną i podkładki i sworznie w niej,tak aby opiłkowała z powodu dużych luzów i nie równomiernego nacisku na pojedynczych wypustach zębatki. Pozdrawiam z PL.

[@techi3075]

As always, excellent video. I’m good with all the regear principles, I was just hoping to see all the details on carrier and pinion shims. As in like what the cause and effect (math) of the shim adj does. Like .001” on the pinion decreases back lash like .003”? I’ve only done 2 regear jobs, a 04 Jeep and a 76 vette. I’ll figure it out though, doing my jk in the next few days after I pull the d44 out. Thanks for taking time to document this😊

[@TheBFHGarage]

I have a JK re-gear video too.

[@stevelewis4348]

First, Great content on jeeps, second with the growing popularity of Jeep WJs for 4x4 builds would you consider re-gear video on the Aluminum Dana 44HD? I re-geared my 44HD from the 3.73s to 4.56 with an ARB and Revolution gears using your KZbin How to re-gear a Dana 44 as a guide, but have gear grinding /winning noise.

[@truckcampertraveler7369]

2 words …. Thank you !

[@jasonhurlbert5593]

I'm getting ready to install a Detroit trutrac in my dana 44 and was wondering if the carrier shims go under the bearings or on the outside of the bearings? Awesome video by the way.

[@samgm3618]

Thankyou

[@SELCOMSERGIO]

is a excelent expicacion.! is good for me... i have a jeep like this... sorry for my wrong inglish...

[@TheSleeeman]

Im so broke im about to install thick gears on my TJ sport D44 3.73 track lock carrier... My plan is to use it until the limited slip clutch discs wear out and then by that time I can either weld the side gears to the carrier/mini spool it or fit in a lunchbox locker as it should be a more dedicated weekend rig by then. Normally Id wait and save up for an ARB or elocker but its my daily right now and unfortunatley the rear pinion nut backed off and smashed the shim pack on a long trip. I luckily caught it early changing the pinion seal and replaced the outer bearing and shims, setting the preload back to 5 inch lbs for the used inner pinion bearing. Ive driven on it awhile with no sounds but im paranoid and just want to take care of it ASAP.

[@robertpc100]

sorry,yes its a yj.all was replaced.actually my brother did the work,but strange part is they replaced the bearings because there was slack in the bearing,just to find out that after changing it still had slack.im gonna tear it down this evening and look at everything.but thanks

[@ruralzj90]

Enjoyed the video. Very informational including your method of removing the carrier and using the drill to spin the pinion, don’t know why I didn’t think of it myself 😂. You seem way more knowledgeable then I am in this subject and maybe you can give me an opinion on a noise I’m having from my gear install with about 1200 miles on them now. If you get a chance here’s the link of the noise. I haven’t been able to get any help what so ever on forums and I’m trying to narrow it down before something is destroyed beyond repair.

[@ruralzj90]

kzbin.info/www/bejne/epWWepafobSEqNU

[@TheBFHGarage]

I listened and cannot hear any noise. The best thing you can do is to take off the diff cover and inspect it. Spin the gears while it's open to see if you can hear where the noise is coming from.

[@ruralzj90]

@@TheBFHGarage Hard to hear over the other loud noises, its a constant noise that starts around 20-30mph no matter the load or coasting it doesn't change in pitch. Thanks for the effort. Im suspecting a damaged pinion bearing. I removed everything last weekend and swapped to a solid spacer or the crush sleeve, it all looked good at the time with nothing obvious. I noticed while turning the pinion to check the preload, it feels as if the pinion skips in a certain spot(like a dead spot while rotating) then you feel it catch again.

[@TheBFHGarage]

@@ruralzj90 When you took it apart were all the pinion teeth there? Any metal chunks or shavings? Sounds like it is missing a tooth. Could be a bad bearing too though. Dana 35's are susceptible to failure!

[@ruralzj90]

@@TheBFHGarage All teeth were present, bearings appeared fine. There was some silver metal in the gear oil but this was the first gear oil change since install so not sure if that's normal from the break in. Even went as far to double check preload 15 in/lbs, backlash .006" & pattern again and all were fine.

[@jeepsandgym4700]

Awesome video this helps a lot! Question though, why do you have to hold the carrier with a glove when you’re checking the pattern?

[@TheBFHGarage]

You need to apply some pressure/resistance to get a good readable pattern. Interpreting a pattern is much easier and more accurate if there is resistance applied when running the pattern. If you don't apply pressure the pattern can easily be misinterpreted.

[@buttonysquare8501]

I’ve heard it’s not super important to be perfectly centered on the marking compound as long as you are a little shallow because it’s much less likely to crack a tooth compared to too deep. With daily driver type lower horsepower vehicles of course that aren’t a race car. I did a 72 mustang and went from 2.79 to 3.55 and I was a little bit more on the shallow side than you ended up but it has held up fine. That motor is a 302 with about 200 something horsepower pretty much stock but with ported heads, small 4 barrel, and a mild cam.

[@zxborg9681]

Watched this and the 44 rubi video. Thanks for explaining all this so clearly. - I'm looking forward to gettin this done on my TJ now I have an 01 TJ with a D44 rear. Build sheet says it came with track lock, but it has a standard carrier now, and theres zero carrier preload. Carrier rolls out of the housing under its own weight. Previous owner did some mods apparently. Should I be looking to add preload with master shims on the outside, or shims between bearings and carrier, or does it matter?

[@TheBFHGarage]

Most likely it will have two master shims to the outside of the bearings. Those master shims will be different thicknesses. With it being an open carrier I would put shims under the bearings and still use the masters to the outside. Make setup bearings for this.

[@zxborg9681]

@@TheBFHGarage Thanks, makes sense.

[@ChristopherBritztopher]

Awesome video, thanks for filming this. Do. you know if there are any differences between the dana 44 rubicon and dana 44 thats in a TJ. I mean besides the locker?

[@TheBFHGarage]

Outside of the pumpkin everything else is the same with the exception that Rubicons all had disc brakes. Inside the pumpkin, the locker is slightly wider than a normal carrier. You can use an aftermarket locker such as an ARB but it'll take a few more shims to get the proper preload. Rubicons also used a thick ring gear.

[@SlurpeeMcFlurpee]

Got a question, watched a handful of your videos and haven’t see this- What if you can hear the backlash from wiggling the pinion but unable to hear the click or get a reading from the ring gear? I assumed that maybe my carrier preload was too much but I’m not using a case spreader so I thought it would be damn hard to do that without a spreader. Can barely move the ring gear by hand. If I do a handful of rotation from the pinion I can eventually get a place to check but not consistently. Appreciate the work you put into your videos. They are a masterclass for someone just learning like me.

[@TheBFHGarage]

It is incredibly difficult to get too much carrier pre-load to where it won't spin. When people ask this question, I tell them to remove the carrier and reinstall it. A lot of the time they will find a shim that fell out of place and got bent behind the race. This causes the carrier to not be seated correctly which can cause the bearing/race combination to be not smooth. Another thought is ring gear run out. If the ring gear is sealed properly and has greater run out than a couple thousandths, it could be a gear issue. Start with pulling it and re-seating it first.

[@ryanpagano2946]

I have a 03 TJ Sport with the factory D44 open rear. I've got a Timken SET 10 bearing set for the axle bearings. Are those bearings also the ones used for the carrier? I've been told Spicer 706032X will work but they seem to be the same as the SET 10. What about the pinion bearings? Excellent video and I'm excited to tackle this job now.

[@TheBFHGarage]

There are so many bearing and race combinations based on brand, axle type, carrier/locker that I always look up exactly what I'm working on. Rock Auto is a good source to sift through all of the stock conficurations.

[@clarkdrago]

Very in depth man, cant thank you for this enough! I do have a few questions though. I've got a 2000 TJ with 44 rear and 30 front with 3.73's. I'd like to do exactly what you've done here in the rear and just regear the 30 to match. I've seen that if I have 3.73 or lower I need "thick" gears to go up. Do you happen to have an exact parts list for everything needed to do what you did in this video. Sorry to ask just a bit confused. Thanks! Just fyi I'm on 35s wanting to go 4.88s or 5.13s

[@TheBFHGarage]

I don't want to add a parts list because it will be different for a Rubicon or if somebody has a high pinion 30 like I do. As far as carrier breaks, the Dana 44 carrier break is 3:73/3:92. What this means is that if you currently have 3:73 and lower (numerically) gears, you will need a new carrier to run gears 3:92 and higher (numerically). You can get around the carrier break by using thick cut gears.

[@clarkdrago]

@@TheBFHGarage I got, thanks for the info!

[@michaelballard4289]

Got a question? 2015 Jeep wrangler Willy’s spider gears broke, replaced and had to replace both passenger and driver shaft bearings and they blew apart!

[@TheBFHGarage]

So what is the question?

[@horiafrunzete1868]

Nice video, one of the few that takes you through the whole process. Quick question: how do you set the carrier bearing preload? I heard you saying: "It should take you a few good whacks" but I'd like to know if there's a more scientific approach. Thanks.

[@TheBFHGarage]

Great question! There is no real way to "measure" carrier preload. When gears are set at the factory, they use a housing spreader and simply drop extra shims in on the side and then release the spreader. If you are installing without a spreader, then the most common way is to add enough shims that it requires you to use a deadblow hammer to set the case all the way. It's a fine line between not enough and too many shims. You shouldn't be able to pull the carrier or by hand. The factory states to not spread the housing more than 15 thousandths of and inch.

[@pcmmulders]

On the Dana 23/25 WW2 axles, the TM states to measure the gap with a feeler gauge, fill it up and add 0.008 to it as preload. Maybe a good reference?

[@TheBFHGarage]

I suppose you could but no need really. I get the carrier to where it's snug to push in by hand and then add shims for pre-load. It should take 6-8 whacks with a deadblow hammer to get it in. With experience you can feel when it's correct based on how hard it is to get in as well as how difficult it is to remove.

[@5400bowen]

There are two videos on Utube that I've found that tell how to set the carrier preload. After you set the pinion preload, you put the carrier in and recheck the preload. You make the career tighter (add shim) until you've added 5-8 inch pounds of torque to whatever the pinion preload was. There are variations depending on the differential make and model, but the only one I found in about 50 to 70 hours of Utube instructionals on differentials was an old differential, like 1970s or earlier. It was SIU automotive that I first heard it from. But at Least one other good video said the same thing.

[@ToddAdams1234]

@@TheBFHGarage OTC sells that housing spreader. Any place that sells OTC tools can get you that tool. Unfortunately it’s almost a different tool for every Dana diff.

[@johnnyb7497]

Masterclass on re-gearing! Where do I sign up for more?

[@TheBFHGarage]

More videos on the channel👍

[@melindaortiz9741]

💯

[@gerin1946]

I put my bearings to warm up in engine oil bath very very hot ! or in the fridge for external fittings !!!

[@Mzandiotis]

I'm finding different information about the slinger in a TJ D44 rear. When I pulled my axle apart there was no slinger between the pinion head and inner bearing. I'm also reading about a stepped baffle, think it goes after inner race and before preload shims? Anyway, I can't even get that stepped baffle in there. I've got a good pattern with the large slinger in place like you did, just wondering before pressing it all together as I didn't have one originally?

[@TheBFHGarage]

I've seen them with and without the slinger and with and without the baffle. I'm not too worried about either. If you have a good pattern, run it!

[@tinbender85]

Aren't there supposed to be seals at the axle tubes in the case? I couldn't tell that they were in there but you sure can see them on my Dana 44.

[@TheBFHGarage]

On a front axle, yes. Rear axle, no. This is a rear axle.

[@gregburls3699]

Good vid! Good instructions! Why no lube while pressing pinion bearing? Reason,or just personal preference? With the right size press,prob dont need lube,but could def help against tiny scratches. Any insight? Thank you. Subscribed.

[@TheBFHGarage]

I have no preference really. I've never had an issue either way.

[@timothmacalistaire7287]

Great video, thanks. One question though, why route the copper line over the ring gear? Seems like a possible issue if that copper line gets snagged...Can you not have the air line bulkhead on the driver side of the ring gear? Sorry total noob with air lockers.

[@TheBFHGarage]

Trying to install it with a short rigid line is very difficult to do without damaging it. Keeping the line long allows it to flex into place. There is plenty of room there.

[@boogerhead0]

Your attention to detail really appeared to have paid off. Looked fine at end of vid. Was this originally an open carrier? And did you add any friction mod to the gear oil?

[@TheBFHGarage]

When I picked up the axle years ago it had a limited slip. I changed out to an ARB. You do not add a friction modifier to an ARB

[@garys7119]

Just a tip make yourself an oversized pinion bearing so you don’t have to struggle getting it off👍

[@TheBFHGarage]

I have set up bearing I use normally. I was trying to reuse a slinger in this video.

[@hondaman4423]

Which axles have crush sleeves? I'm watching videos like yours to learn how to do gears in my JL. Other videos mention crush sleeves, but it didn't seem like yours had one.

[@TheBFHGarage]

This Jeep was a '97-'06 version where the Dana 44's use shims. The front axles on these Jeeps (non-rubicon) use crush sleeves. Rubicons have Dana 44's front and rear and use shims. JK's use crush sleeves. A lot of people choose to replace it with a crush sleeve eliminator as crush sleeves are very difficult to get started and are easy to overtorque. JL's also use crush sleeves. Hope this helps.

[@BrokenDreamsRacing]

Enjoyed the video and have a few of yours added to my playlist. I am refreshing a Dana44 from a ‘79 F150 and putting a Detroit into it. You mention something about high pinion when using the wrench to get the carrier out and move your wench. Where does my wrench need to be on a high pinion to get the carrier out? To first remove the carrier, doubt it has been out in 44 years, any hints or things to think about or try?

[@BrokenDreamsRacing]

After about an hour of trying, I realized and came to terms with A. This is not your first rodeo and it is mine B. You’ve had the carrier out before you used the wrench technique. Ratchet strap and the rafters in my garage did the trick for me. Thanks again!

[@TheBFHGarage]

When using the wrench trick on a low pinion, the wrench goes on the high side, high pinion it goes on the low side. Simply turn the pinion and it should walk right out. If it has high carrier preload then it will require more force. I just did a JL that had a VERY high preload that required me to use a cheater to turn the pinion.

[@TheBFHGarage]

@@BrokenDreamsRacing improvise, adapt, overcome!

[@BrokenDreamsRacing]

@@TheBFHGarage Thank you! I appreciate the quick response to my questions on a two year old video. Time to start install and using your videos as a guide. Thanks again for sharing your experience! Time to get my own.

[@robertpc100]

great video.can you answer quick question please.i changed bearings in rear of 2008 yj with dana 44 rearend and i can still wiggle wheels from side to side a little.that was why i changed them.its still have same wiggle but dont leak.any reason for this ? i dont think it is right.havent taken pumkin cover off,but need expert opinion please.Thank you .and great stuff.Robert

[@TheBFHGarage]

I'm not sure if I understand your question. First, YJ's were made from '87-'95. Secondly, if it's a rotational movement of the wheel, then it would be normal as this would be the backlash (space between the gears) that causes this.

[@tulsayanes5867]

Very well done. How long would you say it took start to finish?

[@TheBFHGarage]

Axle re-gear times vary on whether you are just changing gears, vs. adding a locker, etc. Typical gear change for me including new bearings usually take about 4-6 hours per axle.

[@robertpc100]

i replaced both wheel bearings in a 2008 jeep tj because there was slack in bearing.wheels are tight and so on.well after replacing both sides and seals, there is still slack in wheel if you jack it up and shake it side to side and up or down.just about 1/8 in.maybe less but you can wiggle them both.its a dana 44.i know it should not do this.any ideas as to what it might be?thank you very much.its the rear by the way. thanks.

[@TheBFHGarage]

You are confusing with your multiple posts. TJ's were '97-'06. 2008 would be a JK. If you have any slack like you describe, take it back apart and see what the issue is. Did you remove the old bearing race? Were the nuts tightened all the way? Is your seal oriented correctly? Is something in the way that isn't letting it seat correctly? Take it apart and look at each piece to make sure it is on correctly.

[@genecenora7176]

What state or where are you located, I need a gear change from 3.55 to 4.10 on a 97 Dodge Ram. Great video

[@TheBFHGarage]

Colorado. I only work on Wranglers! Sorry!

[@36browneyedman]

When regearing a lj dana 30-44 with a 42rle automatic transmission do you have to reprogram the tcm for the new gears? 3.08 to 4.56

[@TheBFHGarage]

No

[@JamesSmith-fq2qn]

When setting pinion preload, I see you set the rotational force but when do you torque the nut to ~200lbs? Do you only do that for the final setup?

[@TheBFHGarage]

Yes

[@ItsaJeepWorld]

First: Great Video... I am thinking of doing one just like it. Maybe... Question: Did I miss the Crush Sleeve or solid spacer, or was one just not used or required? When I re-geared my JKU (3x - I beat it up a lot, LOL), JKUs have a Crush Sleeve on the D30 and D44... The '87 Grand Wagoneer D44 I am getting ready to re-gear does not have one. I am a little confused if they are required or not?

[@TheBFHGarage]

TJ Dana 44's use shims instead of a crush sleeve. TJ Dana 30's use a crush sleeve. A common upgrade for a TJ is a high pinion Dana 30 out of an XJ which uses shims. Another option is a crush sleeve eliminator which is a solid spacer that uses shims.

[@ItsaJeepWorld]

@@TheBFHGarage Yes. Aware of those. I appreciate your time and the info. Oh.. you are close to 1k.. keep up the good works.. I’m subscribed to you, hope you have subscribed to mine too

[@ammarazez7230]

I have question: my dana 44 was bent so I bought new housing from the dealer to put the part from the bent one on the new housing, the question is do we need to do all this process or just put the part back, I’m using all same parts because just housing was bent, please I need an answer. Thanks!

[@TheBFHGarage]

All housings are different. You will most likely need to do the entire setup!

[@mr.m5168]

Very nice video ! I am regearing Dana 44 to 4.88 with new Eaton differential, and having problems selecting correct size carrier side bearings shims . What sizes would you suggest to use as a starting point for each side ? Factory original shims are way too thick for new differential. Install kit came with couple thick shims and bunch of paper fin shims. Any suggestion would be really helpfull

[@TheBFHGarage]

There is no magic number. Did you try installing the carrier and couldn't get it in or was there zero backlash when you did? You might have to build a shim stack in place of one of the thicker ones. You might even have to not use the factory ones at all. Usually though you can use one.

[@mr.m5168]

@@TheBFHGarage Thank you for a quick response . I did did build a shim stacks on both sides . unfortunately when trying smack differential in place with dead blow , smaller shims start to bend . I might try use factory shim on one side ( just like you suggested ) and build a shim stack on the other . Thanks again for sharing your knowledge with us amatures !

[@ArialStacy]

is this differential and aluminum housing

[@TheBFHGarage]

No

[@2-manfreeman153]

Appreciate the video.... 1 question thou... Why did you put pressure on the ring gear with your left hand when running your contact pattern????

[@TheBFHGarage]

Pressure causes firm contact which provides for a far more readable pattern.

[@2-manfreeman153]

@@TheBFHGarage I kinda figured but had to ask.... I'm bout to do my 44 GM front.. and need all the tips I can get

[@2-manfreeman153]

So I have a question for you if you don't mind.... I have pulled my pinion gear and it doesn't have a crush collar it has shims... And I'm not regearing it only putting new bearings races and seals I shouldn't have to change my shims... So my question is when I put my pinion back in I just go ahead and tighten companion flange to specified torque and call it a day??? Thanks in advance

[@TheBFHGarage]

@@2-manfreeman153 exactly

[@jesseyjulson1967]

Yup definitely out of my skill set and don’t trust myself to do it yet. I’ll just pay you or a shop to do it 😂

[@AceGoodheart]

I have a 2017 Jeep Jk unlimited Sahara. Dana 30 front, 44 rear. Eventually I'm gonna swap both front & rear axels (outer & inner) out (44 both front & rear) but for time being I just wanna regear to 4.88. Will I be able to use this same ring/pinion gears when I do eventually get new axels and inner axels? Or will I have to buy new 4.88 gears as well? I'm assuming it depends on the inner axel splicer #?

[@TheBFHGarage]

Your question is a bit confusing...You say you have a D30/44 and then you say you are going to swap inner and outer, and then say you will swap out entire axle assemblies for D44/44. Could you please clarify your question?

[@AceGoodheart]

@@TheBFHGarage I'm still using the stock axels and want to regear to 4.88 before my trip this summer. When i eventually swap out my stock axels in a year or two will i still be able to use the same 4.88 ring and pinion, or will i might have to buy a whole new 4.88 ring/pinion depending upon my new axels?

[@TheBFHGarage]

@Ace Goodheart I guess I'm still confused. If you hve a D44 in the rear, why would you swap for another D44? A D30 ring and pinion will not work in a D44 housing.

[@thiyaphea]

GDay great video my question is your locker the RD117 ?

[@TheBFHGarage]

Mine is the RD116. The RD117 can be used for deeper gears if they are thick cut gears.

[@nestorcinotti1457]

@@TheBFHGarage Great video friend, learning tons from you. I have a 2015 JKU sport and have watched all your ARB videos as well. I have a JKU sport with 3.73 and I want to add ARB lockers only. The question is: Have you ever had to enlarg/re-drill the holes of the ARB carrier to 7/16 or 1/2 inch? I am not sure what size the JK has ..... do you? but I want to be prepare before I start the job. The ARB manual says it might be necessary to do it but I can't find information of people doing it .... Cheers

[@TheBFHGarage]

@@nestorcinotti1457 No. Most ring gears now are double drilled for either size do you shouldn't have a problem.

[@nestorcinotti1457]

@@TheBFHGarage thanks for the reply, munch appreciated. So you have only used then 3/8 for your ARB installation? And you have encountered that OEM ring gear do come double drill with 3/8 & 1/2 on the JK’s? Thanks in advance friend

[@TheBFHGarage]

@@nestorcinotti1457 I use whatever the carrier or locker is drilled to

[@Xxazer23]

So i changed the yoke on my pinion and im afraid I over tightened the pinion nut, so i backed it off a little bit. is there any risk that i've ruined my gear pattern and have to reset my backlash?

[@TheBFHGarage]

Depends on what axle... Dana 30, 35, or 44? You simply can't just back it off. I'm guessing you are using a crush sleeve. If so, then you need to get a new crush sleeve. You can only tighten it up to the pre-load amount. Any more than that and it's over crushed and not usable. There shouldn't be any change to your pattern it anything else.

[@Xxazer23]

@@TheBFHGarage it's a rear Dana 44 from a wrecked 07 Rubicon that I put into my 2012 sport. Had to change the yoke and when I put the nut back on I felt like I went a little too tight on the preload. So the only thing the crush sleeve effects is the bearing preload and not the gear mesh? Your video was super helpful and gave me the confidence to attempt a regear myself.

[@richardvalentin584]

Thanks for you video, i want to do my gear in 2007 jeep jk i just bought an 513 gears and this is my first time doing this. My question is what is the name of the tool you use to align the gear? Where i can buy it?

[@TheBFHGarage]

To align the gear? I'm not following you.... Reply with the time you are referring to in the video

[@richardvalentin584]

At min 25:19

[@TheBFHGarage]

@@richardvalentin584 so that's not an alignment tool. That tool is used to check backlash. It's called a magnetic dial indicator. You can pick them up cheap at harbor freight or any other similar store. So based on your question, I would strongly encourage you to review a lot more videos before getting into this and understand the complete process. Otherwise you can really mess things up. A good reference is the BillaVista gear bible which can be found with a Google search

[@richardvalentin584]

@@TheBFHGarage. i see that and this is my first time doing axle gears..I know a little about auto mechanics. I just rebuilt the engine of my jk 3.8 it was the first time I did it and it turned out fine

[@richardvalentin584]

Thank you for you help. Im gonna do it my self because i went to 3 different place and they want from $2000 to $2500 just to do the job. Thanks

[@jcull]

If I’m reusing the same gears and just changing the open carrier to a locker is checking the pinion depth necessary?

[@TheBFHGarage]

Nope you should be good. I would certainly check your backlash and run a pattern both before and after just to compare. You want the same backlash that was in there so the gears run on the same hardened surface.

[@jcull]

@@TheBFHGarage Thanks for the advice.

[@jorgebolivar]

Where do you grab the backlash and such specs? Locker manufacturer, R&P gear manufacturer or Jeep?

[@TheBFHGarage]

Great question! If the gear manufacturer had specs, I use them as to maintain warranty. I taught myself but had a lot of input from a guy who owned a gear shop for 40 years. The factory service manual will tell you to set pinion preload 20-40 in/lbs for new bearings but anyone who has done this long enough will tell you 16-20 is the right range. So long story short, it's a combination of things with some experience.

[@jorgebolivar]

@@TheBFHGarage Thanks! Great and complete answer. I will be regearing my LJ soon, probably will see your video a few more times.

[@TheBFHGarage]

@@jorgebolivar I recently uploaded another gearing video for a Rubicon if that's what you have. I have several gearing videos posted on my channel to help you out.

[@jorgebolivar]

@@TheBFHGarage Defitnetly will look into them. Yes, I have a Rubicon but like to go to 5.38. Thanks!

[@johnbowling798]

I recently purchased Torsen differential for Dana 44 online. Unit is apparently older version but new in box. Gleason MFG part #M005-BB. Dimensions seem same as factory carrier except carrier bearing hub is slightly larger measuring 1.7995. I believe I've found a bearing cone that will work. Looks like the Timken 25590 will be needed instead of the 25577. The shims however won't work. Are you familiar with this situation and how did you solve it.?

[@TheBFHGarage]

While I'm not familiar with the Torsen product specifically, I have had to take a Dremel with a sanding drum to make shims slide over the journal. Aftermarket specs are all over the place as far as accuracy.

[@johnbowling798]

@@TheBFHGarage Do you know the diameter of the Air locker hub of the bearing number that you use?

[@TheBFHGarage]

@@johnbowling798 not off the top of my head.

[@patrickjunge6455]

Are you installing with a Detroit locker? Or what kind of carrier are you using, also where did you get it from? Also if you install a locker or limited slip on one end of a 4x4 vehicle, does it need to go on both ends? Never have found a straight answer for that question

[@TheBFHGarage]

It's an ARB Air Locker. You DO NOT have to put them on both axles. If you change gear ratios, then you DO need to do that to both axles.

[@patrickjunge6455]

@TheBFHGarage one more question, does the ring gear diameter have to match, thinking 8.8" in the rear, 9" front, but matching ratios, 3.55

[@TheBFHGarage]

@@patrickjunge6455 no, not at all. Only the ratios have to match.

[@WorkableWax]

What kind of truck is this in? Looks familiar underneath

[@TheBFHGarage]

It's under a mostly 2000 Jeep Wrangler TJ

[@Overlandlife_]

What’s the chance your close to ga lol I need mine done

[@TheBFHGarage]

You're only about 1500 miles away 😂🤣

[@lnaesll]

What the name of that tool you used to hammer the bearing race in with? The thing that says “US General”

[@TheBFHGarage]

It's a seal driver set. That one is from Harbor Freight.

[@ToddAdams1234]

@@TheBFHGarage you can use the same tool as a seal installer for that application if you haven’t put the gears in yet. Turn the head of the tool around on the handle and then it works GREAT! 😊

[@WestTexasOverlanders]

So after watching your videos and finally building the confidence to do my own gears in my 2015 jk (non-rubicon), I tore my axles apart lastnight and realized my rear dana 44 did not have any inner axle seals. is this normal? and when i do go to install the new inner axle seales i will be installing the new axle/bearing combo from revolution gears, but do i need to pre-grease those outer axle bearings?

[@TheBFHGarage]

In the rear axles, there are no inner seals, only outer seals. The bearings get their lube from the differential, which has to travel down the axle tube. When installing the new axles, put grease on the seal, and then squirt some gear lube on the bearings right as you install them into the axle.

[@WestTexasOverlanders]

@@TheBFHGarage thank you very much for that. I was getting confused as to how they would stay lubed lol. Do you have a Patreon page?

[@TheBFHGarage]

@@WestTexasOverlanders I don't.

[@WestTexasOverlanders]

@@TheBFHGarage well if you do create one, let me know and I would be willing to contribute monthly.

[@TheBFHGarage]

@@WestTexasOverlanders I appreciate that!

[@royvangemert1902]

Why did you think you wouldnt need shims behind the inner pinion race? Every one I do takes around .030"ish,

[@TheBFHGarage]

You can do it one of two ways. Shims behind the race or shims between the bearing and pinion head. I added a slinger between the head and bearing that was thick. I had to change it out to a thinner slinger and added the needed difference behind the race. I could have pulled the bearing off again but decided to just use a set up race to get it dialed in.

[@jimjardine4705]

I didnt see when you put in the spider gears!!!!

[@TheBFHGarage]

Thats because it's an ARB locker.

[@snicks50]

I have never seen anyone make it so compilated ?

[@tweakergarage]

Snicks, can you post a link to your video?