Hey guys, I’m new here and was hoping for some help.

I just picked up a 2007 unlimited that already has a Teraflex 2.5 lift and 33’s. I was wondering if anyone can recommend a decent set up for gearing and strengthening the axles so that I can run 35’s. Im definitely going to wheel this Jeep, but nothing crazy and I want to keep the DD aspect since I’m located in the Sierra Foothills and will only make day trips.

 

It's hard to go to low with that 3.8L. Look at 5.13 gears, throw some C gussets on, go have fun. It that bombproof? No. Will it be good? It will be good and fun till something goes wrong which may or may not ever happen. How do you get bombproof? Full-width 1-tons combined with unlimited budget for everything else. You will see there is no black & white answer to the question posed. That said, you can have a heck of a lot of fun on the build you have and regearing it.

I'm gonna fall into the rabbit hole here but not too deep. The real problem is nobody considers steering, and you can drop a decent bit of coil upgrading drag links, tie rods, ball joints, etc. I'm going to leave it at that as this topic can just go on and on from there.

 

Which transmission?

2007 had a few oddball options from the factory. It was possible to have a D35 rear axle instead of a D44, and it was possible for Non-Rubicons to have a front rubicon D44 along with the e-locker instead of a D30. More than likely you have the standard D30/D44 combo, but just for clarity on the replies you'll get, it might be good to verify what you currently have.

 

I just verified that it’s a 30/44 combo.

 

Which transmission? Lots of personal preference involved, but for the 3.8 engine, 6-spds generally get gear recommendations one ratio lower (numerically) than Auto's. So depending on your actual location/opinion/needs, 5.13 for an auto and 4.88 for a 6-spd are a good place to start.

 

Oh sorry, it’s an auto

 

While it was possible (though difficult due to supply constraints) to get the locker on the rear axle on 2007s, I'm pretty sure it was never offered for the front. Regardless, very few ordered because it was reported as a six to eight month lead time: They needed all of the axles and lockers for the Rubis, which were running really late. I've only ever seen one fellow post here that he had a rear locker. And even he commented that he was told by a mechanic that it was very rare on an X. No one has ever mentioned an OEM front locker that I've seen (but I don't read every post, LOL). As for the rear D35s, I believe those were limited to the very first few Sahara models built.

As for OP's question, I'm running 4.88s with 35s on a six speed X model. I've managed in 267,000 miles to blow one front pinion gear and two rears. My mechanic suggests I should upgrade the rear axle to a D60, and the front to a D44. My problem is weight. I have a very heavy rig--well over 6,000 pounds when fully loaded--which is why I mention this. That is, there is a bit more to your decision, including how long do you intend to keep your Jeep (they can bury me in mine), and how heavy do you think it'll grow. Just food for thought.

 

Yes, 5.13 gears and lockers would be a good idea but I also don't like throwing money into the factory axles. A 60 rear and 44 front or some 9" would be better and stronger for sure but if you are not hard on it and actually know how to drive off road you should be able to get by on the factory axles. Reinforce the inner C's if it has not been done already. If you have an 07 the C's are likely bent already as it is very typical and happens to jeeps that don't even go off road.Steering upgrades would be something to think about as it was mentioned as well as checking out the unit bearings and ball joints. I don't know how many miles you have on it or how it was treated but those are things that are normal wear parts. If you ever go into Reno feel free to contact me and bring it by my shop and I can take a look at what you have. I know I do have a front jk dana 30 in my pile of axles that has 5.13 gears and reinforcements on it. I could swap it onto your rig cheaper then you can get the gears and reinforcements done.

good luck with the new jeep.

 

I would consider 5.13 and axle sleeves. I also did G2 axle shafts and have been very pleased. Beat the heck out of my Jeep.