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Old 02-28-2019, 09:33 AM
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JK regear questions

Can anyone answer the following that will help me with self performing a gear change for D30 & D44 axles

1. Do carrier shims go between the carrier & carrier bearings or do they go between the carrier races & axle housing?

2. Inner pinion depth. Shims between pinion head and inner pinion bearing or between bearing race & housing? Resulting in the need for either a setup bearing or a setup race?

3. Setting pinion preload. Do I need a couple extra crush sleeves & pinion nut per axle or can I get by with using original?

I've done gears before on D44 TJ's. Just looking for differences and what else is needed for install on a JK.

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Old 02-28-2019, 10:52 AM   #2
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Originally Posted by sierradmax View Post
Can anyone answer the following that will help me with self performing a gear change for D30 & D44 axles

1. Do carrier shims go between the carrier & carrier bearings or do they go between the carrier races & axle housing? Between race and housing

2. Inner pinion depth. Shims between pinion head and inner pinion bearing or between bearing race & housing? Resulting in the need for either a setup bearing or a setup race?between pinion head and bearing

3. Setting pinion preload. Do I need a couple extra crush sleeves & pinion nut per axle or can I get by with using original?Yes.
I went through a couple on each axle...lol.



I've done gears before on D44 TJ's. Just looking for differences and what else is needed for install on a JK.
Master install kits are set up this way. Through all the research I have done I believe that if you want to shim the way you did previously and have the correct shims you can still do it the "old" way. Doesn't really matter as long as you get the carrier and pinion in the right spot.

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Old 02-28-2019, 10:56 AM   #3
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1. If I remember correctly, the shims go between the carrier bearing and the carrier. It's been over 5 years since I've done a JK axle and I can't remember for sure. Someone else can chime in who knows for sure.

2. Pinion shims go between the pinion gear and the bearing. You definitely will need a setup bearing for that.

3. You absolutely need to use a new crush sleeve when you are setting up a new pinion. Either that or find a crush sleeve eliminator.


I have no problem doing gears for the old generation Dana 44. A couple of setup bearings and some patience adjusting shim packs is all you need. The crush sleeve on the JK axles is a bear. It takes quite a bit of force to crush the sleeve. That's something I'd happily pay a professional to do.
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Old 02-28-2019, 02:06 PM
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Aside from the tools I have, sounds like I'll need the following:

A set of carrier setup bearings for D30
A set of carrier setup bearings for D44
Inner pinion bearing as setup for D30
Inner pinion bearing as setup for D44
Crush sleeve eliminator kit for D30
Crush sleeve eliminator kit for D44

Having never dealt with a crush sleeve, I take it the principle is to torque the pinion nut down to seat the outer pinion bearing against the race and establish proper pinion load? An eliminator kit is a machined spacer and a bunch of shims to set preload?
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Old 02-28-2019, 02:44 PM   #5
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Yep. The crush sleeve is great for manufacturing because you can have a specialty tool just crank it down, checking preload as it goes. No time consuming changing of shims.

When installing gears, you crush the sleeve up to a point, check preload (just like when you check preload shims on the old 44). Tighten it just a little more, check preload. Repeat until you get it up to spec and you're done. The only problem I had was that the torque needed to crush the sleeve was significant. With a 6 foot cheater bar on the 3/4 drive ratchet it was still a significant effort to crush the sleeve.

I've never used a crush sleeve eliminator kit so I can't comment on how they work. Whether they're adjustable or just a sleeve with shims.
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Old 02-28-2019, 03:51 PM
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3/4" & 6' cheater? Damn... must be a stout tool to hold the pinion yolk.

On a side note, just spent 30 minutes looking at youtube vids. Seems carrier shims are between the race and the housing.... So setup carrier shims would not be required.
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Old 02-28-2019, 04:16 PM   #7
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3/4" & 6' cheater? Damn... must be a stout tool to hold the pinion yolk.

On a side note, just spent 30 minutes looking at youtube vids. Seems carrier shims are between the race and the housing.... So setup carrier shims would not be required.
Correct. No need for carrier set up bearings. Only the inner pinion bearing.
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Old 02-28-2019, 04:54 PM   #8
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3/4" & 6' cheater? Damn... must be a stout tool to hold the pinion yolk.
We used a 4' long pipe wrench to hold the pinion.

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Originally Posted by sierradmax View Post
On a side note, just spent 30 minutes looking at youtube vids. Seems carrier shims are between the race and the housing.... So setup carrier shims would not be required.
I'd believe that. That's the opposite of the old generation Dana44, which is the last couple of axles I did. I couldn't remember for sure how the shims went in the JK.
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1987 MJ - 4.0/BA10-5/D35
1986 J10 - 401/700R4/NP208/D44HD/D60FF

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Old 02-28-2019, 09:21 PM   #9
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Correct. No need for carrier set up bearings. Only the inner pinion bearing.
Beat me to it.

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Old 02-28-2019, 09:26 PM   #10
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Front crush sleeve isnt bad. Rear is just like the guys said. 3/4" breaker bar. 4' cheater that i had to jump on

Crush sleeve eliminator would be how i do it in the future

They didnt make one for the d30 as it was stepped...at least they didnt when i did mine.

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