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Re-gear project

Discussion in 'Builds and Fabricators Forum' started by Project71-5, Feb 18, 2015.

  1. Feb 18, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    After many years of going back and forth between doing this myself or paying someone, I'm finally taking the plunge.:shock: The plan is to get rid of the 3.73's and replace with 4.88's (99.7% sure). With the OD engaged, the ratio drops to 3.66 so it should still be ok on the highway.

    Since the front D30 gears are only turning in 4wd it should be a good learning experience. The spindles are shot so those will be replaced along with all bearings, seals, rotors, etc. I have a press and an ebay carrier bearing puller kit on the way, which is a Yukon knockoff. I'm still undecided on the brand of gears or if I'll keep the Aussie locker up front since this is snow country, although I will admit I rarely drive the Jeep in the snow :rofl::oops: The rear will most likely get either an ARB or Eaton E-Locker.
    [​IMG]

    A full floater kit has also crossed my mind along with a set of Holbrook longleafs but the KTM 350 EXC I've been lusting over might push those plans to the back burner :twisted: More pics to come as progress is made.
     
    Last edited: Feb 18, 2015
  2. Feb 19, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

    USA
    Joined:
    Oct 25, 2006
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    I did something similar a couple months ago. Everything new except axle shafts. Set up my own gears for the first time. The guys here helped me immensely. Mine seems to work as designed and hasn't made any funny noises or exploded yet. Good luck!
     
  3. Feb 19, 2015
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
    Joined:
    Aug 18, 2014
    Messages:
    7,540
    I sold my KTM 450XC to get back into Jeeps, I don't miss it one bit. I'd go with the FF. :)
     
  4. Feb 19, 2015
    Warloch

    Warloch Did you say Flattie??? Staff Member

    Falcon, CO
    Joined:
    Mar 4, 2003
    Messages:
    5,466
    IMOP - the 4.88s with OD are a perfect setup.

    Go with the FF... Its not a question of IF you get hit on a bike, its WHEN... then all that time and money will be shot - happened to me and the only two boys that rode - youngest decided to NOT go that route :)
     
  5. Feb 19, 2015
    tymbom

    tymbom Member

    Siskiyou Co.
    Joined:
    Jun 13, 2012
    Messages:
    814
    I sold my KTM 525exc and bought a Jeep as well.... My wife and daughter found it a little easier to come along. X2 FF and longleafs
     
  6. Feb 19, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    I already have a dirtbike, this would just a nice upgrade. I wonder if I could talk the wife into letting me do everything.
     
  7. Feb 19, 2015
    Jasontg

    Jasontg Member

    Georgia
    Joined:
    Feb 6, 2014
    Messages:
    136
    I you figure out how to talk your wife into letting you do everything you want you can sell that info and will become a millionaire.
     
    Last edited: Feb 19, 2015
  8. Feb 19, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

    USA
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    Yeah, im not allowed a motorcycle.
     
  9. Mar 13, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    Well I finally have all of the parts I need minus new Warn Premium hubs and the spindle thrust washers. Those parts will be here Monday. I scored a great deal on the Nitro gearsets and master install kits from a vendor on Pirate4x4, BareFoot Offroad, but I'm still shopping for the rear locker. Originally I was going to remove the front Aussie Locker to make it possible to drive the Jeep in the snow if needed. I've since decided against that as I realized that I really don't take the Jeep out during the winter because of all the Mag Chloride that gets put on the roads around here. Here is the latest:

    Durasolid brand carrier bearing puller from Ebay. This shipped direct from India and is an exact replica of the Yukon model. I wouldn't be surprised if the Yukon model is made at the same plant. Everything is very nicely made and it was less than half the price of the Yukon.
    [​IMG]

    New balljoints, rotors, bearings, etc.. all ready to go
    [​IMG]

    Installed the axle shaft seals last night
    [​IMG]

    No plans for this weekend as of yet, so hopefully I'll be able to get the gears setup and most of the other parts installed 8)
     
  10. Mar 15, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    Anyone care to critique my final pattern?

    Drive
    [​IMG]

    Drive 180 from first photo
    [​IMG]

    Coast
    [​IMG]

    Coast 180 from first coast photo
    [​IMG]

    The ring gear has a bit more runout than I would like which makes it hard to get the backlash consistent. It is in the gear not the carrier. However it is within spec all the way around. The last coast photo shows the deviation. I feel that this setup is acceptable for a front axle as all the photos fall in the acceptable patterns in Nitro Gears literature. Anyone think otherwise?
     
  11. Mar 16, 2015
    Warloch

    Warloch Did you say Flattie??? Staff Member

    Falcon, CO
    Joined:
    Mar 4, 2003
    Messages:
    5,466
    Not an expert, but they look good for a front axle to me.
     
  12. Mar 16, 2015
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

    USA
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    Oct 25, 2006
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    I am not an expert either and have only done one setup. I was hoping someone else with real knowledge would speak up. heres a bump.
     
  13. Mar 16, 2015
    uncamonkey

    uncamonkey Member

    Greeley CO
    Joined:
    Jun 2, 2009
    Messages:
    2,104
    Run 'em, as long as you aren't running 35' tires.
     
  14. Apr 2, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    Well I decided to stick with that pattern for the front. I finished building the front axle and pulled the rear last Monday. If all goes well I should be able to get the rear cleaned, painted, and hopefully get the gears and Yukon Zip Locker setup this weekend. :)
     
  15. Apr 3, 2015
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
    Joined:
    Aug 7, 2003
    Messages:
    4,538
    Looks good to me. I'd go with it.
     
  16. Apr 3, 2015
    Posimoto

    Posimoto Hopeless JEEP Addict

    Minden, Nevada
    Joined:
    Aug 7, 2003
    Messages:
    4,538
    Just ordered one of those bearing pullers (carrier bearing) That's a good deal and I have at least one more set of gears to setup.
     
  17. Apr 7, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    Well I managed to get the housing cleaned, painted, and prepped along with all of the small parts. I started to mount the ring gear to the Yukon zip locker but noticed that the locker is drilled to accept 7/16" ring gear bolts and all I had were 3/8". Apparently D44's used both 3/8" and 7/16" ring gear bolts. Luckily the Nitro Gear gears are drilled to accept either so I ordered the larger bolts last night and hope to have them by the end of the week.

    I did notice that the carriers and bearing locations were quite a bit different between the two carriers. I assume that this is because one is a series 3 carrier and the new locker is a series 4? Also because of the seal housing on the new locker? I'm just concerned that the bearing cap won't fully capture the bearing on the new locker.
    [​IMG]
     
  18. Apr 7, 2015
    Mike C

    Mike C Member

    Austin, TX
    Joined:
    Feb 19, 2007
    Messages:
    743
    Yes they are different heights because of series. The ring gear mounting flange moves closer to the pinion center line on the 4 series carrier. As the ratio number increases, the diameter of the pinion decreases so the ring gear is moved closer so the gears mesh correctly. If everything is machined correctly, you should have no issues.
     
  19. Apr 11, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    Here is today's progress. I'm still debating on the pattern and need opinions.

    Backlash at .008
    Pinion depth shim at .025"

    Drive
    [​IMG]

    Coast
    [​IMG]

    Pinion depth looks pretty good on the drive side but possible shallow on the coast? This is only my second setup so any feedback is greatly appreciated :beer:
     
  20. Apr 11, 2015
    Project71-5

    Project71-5 BACON

    Gypsum, CO
    Joined:
    Sep 24, 2002
    Messages:
    897
    Whipped up this housing spreader as well.
    [​IMG]
     
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