Hello all,
I have been lurking here for some time and due to my current station in Germany have been unable to modify said Jeep at all. The good news is I am returning to the states for good in about two weeks and the first of many mods are going to be a gear swap. I will eventually follow in Planman's step's with 40's except I am going to stretch the Jeep 8". Anyhow, I would like to know those of you that have done a gear swap yourself (yes I realize taking it to a shop with warranty and ease is easier, but I like to work on it myself) what are the major hassles? I have a Rubicon so i have factory lockers. Is a case spreader a nicety or necessity? I have all the other tools, so any info would be great. I have read the excellent gear swap write up here a couple of times, but I am looking for others that have done the swap to chime in....

 

https://www.jk-forum.com/forums/show...8112-It-begins....

https://www.jk-forum.com/forums/show...?82262-Gearing

 

Hey! Allow me to be the first to welcome you to the forum!

Now about the swap, I have had the pleasure of doing a front JK axle (mine) and the rear axle of a TJ (friends). Still have probably 3 more swaps to do. Anyways, I can tell you it is a little bit overwhelming the first time, but very rewarding, to do it yourself. As for the tool listing, I have been able to do it without the case spreader. Can't comment on whether or not it would have been nicer, I'm sure it would have, but not necessary. Outside of that, having the correct tools, measure measure measure. Alot of measuring. It's almost impossible to find an in/lbs dial indicating torque wrench around here, but you need that one. Can't really get around it unless you are comfortable with guesstimating. Wouldn't reccomend that one! Besides feeling awesome that you did something so significant to your Jeep, you do save alot of money. In most cases it's enough that if you screw it up the first time, you can buy all new parts and do it again in what money you saved in labor. Yukon has a great little book that comes with their gears. I know I am leaving out alot of stuff, but I hope you decide to do it yourself...

 

Huh, I haden't seen that first one. It's pretty good too.

 

Thanks a lot for the information. I am a mechanic in the Air Force and we do nothing but measure. I think I will be good there. It seems like patience is the key to this and I am looking forward to trying it out.

NTHINUF thanks for the links. I have been on this forum for a long time and have not seen the first one like no1ap. I appreciate the responses...

 

I made gears myself couple weeks ago, first time,
here is documented story: https://www.me.com/gallery/#100111

- have all the tools, long break bar for crushing sleeve specifically,
- dedicate time for it, it may take couple (several) times to get right backlash and pattern, took me 9 times,
- use forum for advises as you work (I did post pictures of the pattern as I was working)
see this: https://www.jk-forum.com/forums/show...ighlight=mituk

good luck

 

Thanks a lot mituk. The pictures you took of the yellow paint will be a big help. I could not however access your write up, but I am at work so that probably has something to do with it. Appreciate the info...