Gear Swap writeup

[rockdawg]

For anyone considering replacing his or her own gears here is a quick write-up.
I will over simplify this as the links I have added below go into great detail.

Replacing the ring and pinion requires the gears to be set-up.
This requires shimming the carrier bearings and setting the pinion depth.
This ensures that the gears contact each other at their sweet spot, and that proper backlash (play) is achieved
Marking compound (like paint) is used to check this.

Below is a picture of a good contact pattern
http://zukaz.tripod.com/gears/chris43.jpg
Below is a pic of a dial indicator being used to check backlash
http://www.4x4wire.com/jeep/reviews/488/Dcp01463.jpg
To do the gears you'll need:
calipers or micrometer
inch-lb torque wrench
ft-lb torque wrench
bearing puller (clamshell type)
Dial indicator
Optional tools to make everything easier:
3-jaw puller
20 ton Press
Most good rental places have the tools you will need if you don’t own them.

In the pic below you will see the carrier (the ring gear bolts onto this), the 4bolts and straps that hold it in.
http://www.geocities.com/lars915/Images/d44_complete.jpg
As a side note: the pic above shows a lockright locker installed in the carrier. When you hear the term “lunchbox locker” it is referring to a locker that installs in a stock carrier. A full locker such as a Detroit replaces your stock carrier with a new one.

In the pic below you can see the pinion gear with the carrier removed
http://www.off-road.com/dodge/ramcharger/tech_tips/images/Inside_Front_Axle_Housing_Pinion.jpg

Below are some links to good write-ups on swapping gears. Use these and the instructions that come with the gears (as they will have specific’s pertaining to your axle) and you should be able to tackle the install.

The first link is great for reference, basic understanding, and specifics pertaining to many popular axles.

The second one is more of how it’s done in the real world and full of tips and tricks. :wink:

http://www.drivetrain.com/ringpinioninstal.html

http://www.pirate4x4.com/forum/showthread.php?t=108819&highlight=gear+installatio n

HTH, al

[NYWheeler]

Looks like your missing a couple of axle tubes. :lol:

[rockdawg]

Looks like your missing a couple of axle tubes.
Hey- when I want to narrow a rear I narrow it!

Actually I just stole the pictures off the internet :wink:

[ROCKREADYXJ]

We re tube axles if you need that done

[ROCKREADYXJ]

+ a case spreader

[XEON]

I found a nice write up in PDF format. Check it out in attachment:

[matt6669]

thanks justin thats a pretty good write up.

Im getting ready to buy my yukon gears and install kits very shortly so ill be doing my gear swap very shortly. I can't wait to throw that d44 into my truck ahhhh im soooo pumped

Matt

[ROCKREADYXJ]

That is a very generalized article. remember that not all axles get set up the same there are some slight differences.The best manuals for gear set ups are original mfg books. there are also a couple different ways to acieve the same end result. I prefer to set up dana/spicer axles different than listed in that pdf. I use the dana instal procedure I have always found it to be faster and more acurate on the first time. I was taught the same way listed in the pdf but I never use that procedure any more.

[NYWheeler]

Yeah there is always more than one way to do things. None are wrong but some are easier than others. As long as everything is within spec when your done than you'll be fine. As long as you have a good mechanical ability and some common sense than you can get it done.

[XEON]

Found this nice little chart for you DIYers :). If its wrong, let me know and I will remove it or edit it.


This picture was found on Pirate4x4.com.

[ROCKREADYXJ]

nice picture Justin but any one looking to do this the pattern will not be that drastic. But that is a dam good reference

[XEON]

Great write up on gear install here:
http://www.pirate4x4.com/articles/tech/billavista/Gear_Setup