gears and intstallation
Thread Starter
JK Newbie
Joined: Mar 2010
Posts: 4
Likes: 0
From: killeen, texas
gears and intstallation
this is my first post so im gonna try to word this right. about a year ago i put some new tires on the jeep and i have almost completely lost 6th gear as well as all uphill momentum but im sure everyone knows this. i have recently bought some 4.88 gears for my rear end and ive heard that the front axle gears are reverse cut. is this true? i have an 08 jk with a dana 30 front axle. im going to attempt to do the work myself with the help of a competent friend. does anyone have any words of wisdom for a novice?
JK Super Freak
Joined: Mar 2008
Posts: 1,673
Likes: 3
From: Alberta
JK Newbie
Joined: Oct 2009
Posts: 29
Likes: 0
From: AZ
Go For It
I did my own gear a few weeks ago. Just research the tools you need and you should be ok. BlackNorthernJK has an excellent writeup and the tools needed. Some of the specialty tools I can think of are:
-- Press (bought a 12 ton from HF)
-- Large bearing separator (also from HF)
-- Front axle kit, for large metric sockets (29mm-38mm) (also from HF)
-- Flange wrench (had my own made, but my cousin is a machinist)
-- case spreader...some may argue it's not needed, but it sure does speed up the process of removing and installing the carrier. This was also made by my cousin.
A few things I noted from the Motive Gear overhaul kits...
-- The dana 30 crush sleeve which came with the kit was too thick and impossible for us to crush. I broke two ratchets and almost broke a breaker bar. Luckily I purchased spare crush sleeves from the dealership just in case. The OEM sleeve went right in. Purchase spare crush sleeves and take them back if they are not needed.
-- I just did a TJ's rear dana 44 last weekend and the shims which came with the Motive gear overhaul kits were not the correct size (for the carrier or pinion). They look like they were thrown in there at the last minute in baggies. LUCKILY, we were also installing an ARB locker as well and were able to use the carrier shims from the ARB install kit. For the pinion I had some shims left over from my dana 30 gear install (luckily they fit). I would purchase extra shim packs from some other vendor.
I would like to note I am not a mechanic and I haven't touched a wrench in 7 or so years (since my last 4wd). As long as you are competent in research, problem solving, and common sense you will have no problem. It is a task, but it is great feeling to know you completed the work yourself.
I allowed one weekend per axle. I have about 1000 miles on them and haven't had any problems. We'll see how they hold up offroad.
Have at it....
-- Press (bought a 12 ton from HF)
-- Large bearing separator (also from HF)
-- Front axle kit, for large metric sockets (29mm-38mm) (also from HF)
-- Flange wrench (had my own made, but my cousin is a machinist)
-- case spreader...some may argue it's not needed, but it sure does speed up the process of removing and installing the carrier. This was also made by my cousin.
A few things I noted from the Motive Gear overhaul kits...
-- The dana 30 crush sleeve which came with the kit was too thick and impossible for us to crush. I broke two ratchets and almost broke a breaker bar. Luckily I purchased spare crush sleeves from the dealership just in case. The OEM sleeve went right in. Purchase spare crush sleeves and take them back if they are not needed.
-- I just did a TJ's rear dana 44 last weekend and the shims which came with the Motive gear overhaul kits were not the correct size (for the carrier or pinion). They look like they were thrown in there at the last minute in baggies. LUCKILY, we were also installing an ARB locker as well and were able to use the carrier shims from the ARB install kit. For the pinion I had some shims left over from my dana 30 gear install (luckily they fit). I would purchase extra shim packs from some other vendor.
I would like to note I am not a mechanic and I haven't touched a wrench in 7 or so years (since my last 4wd). As long as you are competent in research, problem solving, and common sense you will have no problem. It is a task, but it is great feeling to know you completed the work yourself.
I allowed one weekend per axle. I have about 1000 miles on them and haven't had any problems. We'll see how they hold up offroad.
Have at it....
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JK Freak
Joined: Dec 2009
Posts: 701
Likes: 0
From: Quebec, Montreal
I did my own gear a few weeks ago. Just research the tools you need and you should be ok. BlackNorthernJK has an excellent writeup and the tools needed. Some of the specialty tools I can think of are:
-- Press (bought a 12 ton from HF)
-- Large bearing separator (also from HF)
-- Front axle kit, for large metric sockets (29mm-38mm) (also from HF)
-- Flange wrench (had my own made, but my cousin is a machinist)
-- case spreader...some may argue it's not needed, but it sure does speed up the process of removing and installing the carrier. This was also made by my cousin.
A few things I noted from the Motive Gear overhaul kits...
-- The dana 30 crush sleeve which came with the kit was too thick and impossible for us to crush. I broke two ratchets and almost broke a breaker bar. Luckily I purchased spare crush sleeves from the dealership just in case. The OEM sleeve went right in. Purchase spare crush sleeves and take them back if they are not needed.
-- I just did a TJ's rear dana 44 last weekend and the shims which came with the Motive gear overhaul kits were not the correct size (for the carrier or pinion). They look like they were thrown in there at the last minute in baggies. LUCKILY, we were also installing an ARB locker as well and were able to use the carrier shims from the ARB install kit. For the pinion I had some shims left over from my dana 30 gear install (luckily they fit). I would purchase extra shim packs from some other vendor.
I would like to note I am not a mechanic and I haven't touched a wrench in 7 or so years (since my last 4wd). As long as you are competent in research, problem solving, and common sense you will have no problem. It is a task, but it is great feeling to know you completed the work yourself.
I allowed one weekend per axle. I have about 1000 miles on them and haven't had any problems. We'll see how they hold up offroad.
Have at it....
-- Press (bought a 12 ton from HF)
-- Large bearing separator (also from HF)
-- Front axle kit, for large metric sockets (29mm-38mm) (also from HF)
-- Flange wrench (had my own made, but my cousin is a machinist)
-- case spreader...some may argue it's not needed, but it sure does speed up the process of removing and installing the carrier. This was also made by my cousin.
A few things I noted from the Motive Gear overhaul kits...
-- The dana 30 crush sleeve which came with the kit was too thick and impossible for us to crush. I broke two ratchets and almost broke a breaker bar. Luckily I purchased spare crush sleeves from the dealership just in case. The OEM sleeve went right in. Purchase spare crush sleeves and take them back if they are not needed.
-- I just did a TJ's rear dana 44 last weekend and the shims which came with the Motive gear overhaul kits were not the correct size (for the carrier or pinion). They look like they were thrown in there at the last minute in baggies. LUCKILY, we were also installing an ARB locker as well and were able to use the carrier shims from the ARB install kit. For the pinion I had some shims left over from my dana 30 gear install (luckily they fit). I would purchase extra shim packs from some other vendor.
I would like to note I am not a mechanic and I haven't touched a wrench in 7 or so years (since my last 4wd). As long as you are competent in research, problem solving, and common sense you will have no problem. It is a task, but it is great feeling to know you completed the work yourself.
I allowed one weekend per axle. I have about 1000 miles on them and haven't had any problems. We'll see how they hold up offroad.
Have at it....
"easy work"... without your cousin and everything it seem to be more complicated.. I was looking for some tool to do it too but I still can't find your cousin on ebay.. and i've tried several keyword.. 
Seriously, be aware that if its a DD JK, get ready to take a week off to make both side... and rent a cousin with a toolbox.
IMO, get a serious shop and let them do the job for you.
JK Newbie
Joined: Oct 2009
Posts: 29
Likes: 0
From: AZ
I do many more complicated things everyday in my career. I didn't think it was a big deal. But it is quite a bit of work. The tools I had made can also be purchased (case spreader and C-3281 flange wrench from Miller special tools). I guess I am lucky.
I decided to take on the challenge for two reasons.
1. Education, I just like learning new things.
2. If I ever break down on the trail I know I can make the repairs myself. I don't really like relying on other people to take care of my problems.
Please note, this is strictly my opinion, and I realize it may not be the opinion of many others.
I decided to take on the challenge for two reasons.
1. Education, I just like learning new things.
2. If I ever break down on the trail I know I can make the repairs myself. I don't really like relying on other people to take care of my problems.
Please note, this is strictly my opinion, and I realize it may not be the opinion of many others.
JK Freak
Joined: Dec 2009
Posts: 701
Likes: 0
From: Quebec, Montreal
I do many more complicated things everyday in my career. I didn't think it was a big deal. But it is quite a bit of work. The tools I had made can also be purchased (case spreader and C-3281 flange wrench from Miller special tools). I guess I am lucky.
I decided to take on the challenge for two reasons.
1. Education, I just like learning new things.
2. If I ever break down on the trail I know I can make the repairs myself. I don't really like relying on other people to take care of my problems.
Please note, this is strictly my opinion, and I realize it may not be the opinion of many others.
I decided to take on the challenge for two reasons.
1. Education, I just like learning new things.
2. If I ever break down on the trail I know I can make the repairs myself. I don't really like relying on other people to take care of my problems.
Please note, this is strictly my opinion, and I realize it may not be the opinion of many others.
But again, nice job. yes you can be proud.
