Re-gearing (gotta start somewhere)

[Flivver250]

A buddy and I are taking a stab at our first regear effort. 4.56's. I already had most of the required tools and added an inexpensive press to the mix (it works just fine). Figured we can't do it worse than the local for hire talent and we are being careful, thoughtful and unhurried. Started on the rear with all new track lok clutches, new axles and all the other bits. Being exceedingly fussy with measurements and patterns. Will start on the front today. Again, all new bits and parts and we have the added bliss of a rust free environment. My rig will probably be next with some 4.88's. I think we are doing it correctly. We put the diffs on the workbench and it is nice working standing up for a change. Getting too old to lay on the floor and flop around like a circus contortionist. I'll lt you know the outcome and a follow-up report after a good break-in period. I doubt I am the oldest ring and pinion virgin out there, but it is about time I popped that cherry.

 

[Rick Flair]

It’s not rocket science. Take your time and measure. That is the part that most fuck up.

You got this.

 

[Tldelaney]

Atleast your working on your buddies first. I joke and say I'd be happy to learn how to regear as long as the first one isn't my jeep.

 

[Flivver250]

Thanks. We have been exceedingly careful and I suspect it will go just fine. We are actually having fun and the work bench has been doubling as a picnic table as we are dining on local delicacies while we take our time. Our buddies have wives and mothers that are contributing amazing calories to the cause.

 

[Flivver250]

Atleast your working on your buddies first. I joke and say I'd be happy to learn how to regear as long as the first one isn't my jeep.

I think we might be more dangerous on the second job when confidence overrides caution.

 

[Brianj5600]

I would pull the whole axle and do it on a work bench. I used jack stands to make it easy rotate the axle on the bench. Having a scissor jack, bottle jack or blocks of wood is nice to be able get the housing at the angle you need. Lastly, keep adjusting until it is right, not close enough.

 

[BeavisTJ]

Sounds like an exciting and rewarding task to tackle. I have no experience in the process other than reading you need some specialised equipment so I'll be following along with interest.

 

[Jerry Bransford]

This is the best how-to gear install writeup ever.... https://www.pirate4x4.com/threads/gettin-the-gears-done.2704422/

 

[JeepingNet]

I was lucky enough to watch someone install my gears the first time. It was important to watch how careful he was and how accurate it really needs to be. I think if I had done it (this was 15-20 years ago) I would have said oh that's close enough and destroyed them. For anyone who hasn't done gears, it can be a good amount of work to re-shim a pinion depth and can take a crazy amount of attempts.

Now when I do them I make sure I have no pressure to get them done right away and will almost always get them set up, call it a night and then come back the next day and do a final check to make sure I still agree.

 

[Vinman]

I did my first ever own re-gear last year and between this forum and Youtube it was relatively easy. Check Billavistas dana 60 regear bible, it has a ton of good info that carries over the the other Dana axles. And I completely agree with have the housings on a bench.

Re-gearing used to be a big no-no for novice or DIY mechanics but with the internet all the help you ever need is a few keystrokes away.

When I did mine I repeatedly posted pictures of my gear patterns as I progressed and had no shortage of good folks here advising what to change to make it better. In the end I had a good pattern and within spec for both backlash and pinion preload which resulted in a quiet gear set that showed no abnormal wear when I sold the Jeep about 8,000 km later.

 

[1904-06LJR]

Check out some of @hosejockey61 videos on youtube (the BFH garage). His regear videos are very informative.

This is also a very good write up:

https://wranglertjforum.com/threads/how-to-install-gears-in-your-tj.2651/