Has anyone here done a re-gear on the Dana 44's in the Rubicon? Can you tell me about it?

I have done many re-gears on Ford 8.8 axels in mustangs and I have the right tools to set up the pinion depth and backlash properly. I am wondering if there is anything that would make this job different in the Dana 44 w/ locker.

Also, will any of the currently avalible diff covers for Dana 44's work without problems on a Rubi?

Thanks,

Mike

 

I have now clue about the gear change, but I have read a little about the diff covers. You'll need a diff cover that has a flat section between the top right bolts. This section holds the locker wire support bracket. For most aftermarket covers this is a non-issue. But you can see in the picture below, that it could be an issue for some. It's my understanding that otherwise it's a standard D44 diff cover.

Picture of a Rubicon style cast D44 diff cover

7/11/07 Added some detail in post number 6. Be sure to check it out.

 

A friend of mine has done three.
He stated that you need to remove the locker switch prior to pulling the carrier. He did not and broke it. Of course the jeep dealer's are giving them away for free. Yeah right!

The other surprise was the crush sleeve and external shims (aka D35 style).

I read somewhere here that the ring gear bolts had changed diameter sometime during the first few months of production, but my buddy did not mention having any issues.

 

Can you post a link (or PM me) where to get that cover?

 

I just ordered one from Offroad Evolution. http://www.offroadevolution.com/

I don't think that they show them on there website, but you can call them.

 

Well as it turns out Offroad Evolution does not sell the Riddler Diff covers, but I know that they have similar products.

I also found out that there may be more to this than I originally thought. I had one guy tell me that for some diff covers, you need at least two inches of lift. I'm not sure why, but this goes to show that you really need go get a commitment from who you buy it from, to make certain that it will fit your application.

 

That makes no sense. I would definitely like an explanation as to how that could be.

 

Woods,

Thanks for this info. I was waiting for some Crane CHC covers, but decided to get the Riddlers instead. I didn't realize I needed that cut-out. :-)

Thanks!
js.

 

Well with a little more digging, I heard that some diff covers will interfer with the JKS adjustable track bar.

Dude, I agree completely. I'm only telling what I'm hearing. If it doesn't make sense, then it's most likely not true. That's why I'm only buying with dealers that will stand behind their products.