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Old 07-14-2016, 05:05 PM
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Upgrade gears/ axles

So I'm looking to upgrading my gear ratio from 3.07s to 4.56 because I want some bigger tires. I am aware I need to carrier lockers but there's locked and selective lockers but I'm not sure which I should get. I'm mostly using mine as a daily driver so I don't need anything off road crazy or anything. I called a shop and said I wanted new gears with Dana 30 for front axles and 44 for my rear axles and he said I would need to change my entire rear axle just for the gears which bumps up the price so much. If anyone has done this project just let me know what you did. Thanx.

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Old 07-14-2016, 05:52 PM   #2
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I know the D30 has a carrier break, not sure if the D44 does. Assuming yours is factory US model, you have the D35.

Selectable lockers are more expensive because you can either be completely open or completely locked. Other lockers like lunchbox lockers will lock whenever there is X amount of torque applied to them. Mine locks whenever I turn the wheel 10, I was hoping to get more slip out of it.

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Old 07-14-2016, 06:43 PM   #3
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I recently went from 3.07's to 4.56 in my YJ. I bought a new carrier for the D30 and used a spartan locker. For the rear I went with a ford 8.8 they are pretty much the same width, as the d35, same bolt pattern , have disk brakes , relativly cheap , not to mention stronger then a d44. The also dont have a carrier break.
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Old 07-14-2016, 07:41 PM
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This guy at the shop I called looking for info and pricing said I'd have to do a complete new rear axle assembly just because I want to add the new 4.56 gears and I'm keeping the 30d in front but I'm changing the rear to the 44d. In addition I still need new carriers so I don't understand why I need a new axle assembly. Maybe the guy was just trying to sell me or something. Shine some light on this?
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Old 07-14-2016, 08:03 PM   #5
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As tomyj says. Go the Ford 8.8 out of an Explorer. By far the cheapset, strongest route. And the Ford 8.8 is everywhere. Should be easy to find a donor.

https://www.wranglerforum.com/f218/su...a-1771657.html
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Old 07-14-2016, 08:26 PM
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I'm looking into the 8.8 swap as an open mind but to continue off of what I was trying to figure out first, if it was really necessary to do a complete axle swap just to upgrade to 4.56s?
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Old 07-14-2016, 09:36 PM   #7
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Your 92 probably has a D35 rear. A D44 is a completely different animal, hence the complete assy to make the change. As others have said the 8.8 is a stronger and more cost effective solution.
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Old 07-14-2016, 09:50 PM   #8
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I see what you're getting at.

Gear ratio is determined by ring and pinion. Regearing means putting in new ring and pinion and "setting the gears." Axle swap is not needed. Go on Rock Auto, drive train, differential ring and pinion. Browse around there for a minute.

Now if you're gearing that high, you probably want to either do some slower crawling or you have bigger tires. Both are reasons to upgrade the rear. For the cost of setting gears in the current axle, you could set the gears in the Ford 8.8 and the swap is done with the exception of wheel bearings/seals and spring/shock mounts.

So to answer your question, gears can be set by replacing the ring and pinion to the proper ratio, replacing carrier and pinion hardware. Plus the front carrier. If you replace the carrier, you might as well put in a Detroit Tru Trac limited slip or a selectable locker like Ox.
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Old 07-14-2016, 09:52 PM   #9
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You can put 4.56 gears in your current D35 axle though. You don't have to get a D44, but it is a smart move for the improved strength.
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Old 07-14-2016, 09:52 PM   #10
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if it was really necessary to do a complete axle swap just to upgrade to 4.56s?
no, but your D35 will probably not hold up well with the extra torque and/or a locked differential.
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Old 07-14-2016, 10:24 PM
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I think maybe later down the road an 8.8 would be something to save up for but for now I'm not really looking to break the pocket or go all out extreme. I just want to add some bigger tires for the lift I got and make my jeep look good. Plus I'm not in a place where there's much off roading available to me. So I've looked at some lockers and I've come across some Dana spicers that were fairly cheep then I looked at the Detroit tru trac and lastly some ARB but those are expensive. What's the word about getting selective lockers that ride better compared to the stock-like ones that are locked?
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Old 07-14-2016, 10:55 PM   #12
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The permanent lockers are locked all the time. If you know how a locker works(sounds like you do) then you should understand how it will effect cornering and making tight turns on pavement. If you get a selectable locker then you have an open diff until you decide to lock it, which means the on road performance you currently have is not changed unless you have the locker selected/on.
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Old 07-14-2016, 11:38 PM   #13
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If you don't plan on much off roading where you might need a locker, get some 4.10 donor axles and slap them in. How big a tire do you plan on? I was on 3.07's with 33's(don't plan on any bigger) and went the east coast gear supply route. You can get it cheap and bolt in ready or you can pick from a lot of different upgrades and spend a lot! I think around $600 with 4.10's ready to bolt in. Now these aren't refurbished they just weld the perches and shock mounts depending on your current lift. Do you have a sye yet? I'd do that first if you don't.

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Old 07-15-2016, 12:39 AM   #14
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You can put 4.56 gears in your current D35 axle though. You don't have to get a D44, but it is a smart move for the improved strength.
There are excellant upgrades for a D35 to handle 35s.
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Old 07-15-2016, 03:37 AM   #15
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There are excellant upgrades for a D35 to handle 35s.
I agree. Just tossing in chromoly 27 spline axle shafts and a Detroit Truetrac will handle 33's nicely - adding the bonus of a good limited slip and a 25% boost in axle strength.
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Old 07-15-2016, 11:03 AM
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If you don't plan on much off roading where you might need a locker, get some 4.10 donor axles and slap them in. How big a tire do you plan on? I was on 3.07's with 33's(don't plan on any bigger) and went the east coast gear supply route. You can get it cheap and bolt in ready or you can pick from a lot of different upgrades and spend a lot! I think around $600 with 4.10's ready to bolt in. Now these aren't refurbished they just weld the perches and shock mounts depending on your current lift. Do you have a sye yet? I'd do that first if you don't.

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Well I planned to go 4.10 at first but with the 4.56 I'd get the best performance for the 33s I want to slap on there. I already have a custom tom woods sye so it's already customized to the specifications I need it to be. Changing to much might through off the measurements it was built to. That's what I'm am trying to avoid.
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Old 07-15-2016, 12:19 PM   #17
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Well I planned to go 4.10 at first but with the 4.56 I'd get the best performance for the 33s I want to slap on there. I already have a custom tom woods sye so it's already customized to the specifications I need it to be. Changing to much might through off the measurements it was built to. That's what I'm am trying to avoid.

It is possible to find the rear Explorer 8.8 with 4.10 and front Dana 30 with 4.10. Thus should help reduce your upfront costs. Regear later to 4.56. Do NOT put money into a rear Dana 35. Save your money.

4.10 d30 usually came in the 4cyl. MORE (mountainoffroad.com) has what you need for the conversion. There are other great vendors than can also assist.

Don't be afraid to check the next major metro area from where you live. I have driven two hours for items at significant savings.
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Old 07-16-2016, 06:50 PM   #18
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is the 8.8 a little narrower i was told i might have to run spacer is this true
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Old 07-16-2016, 06:52 PM   #19
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is the 8.8 a little narrower i was told i might have to run spacer is this true
Its about 3/4" per side. Im not running spacers. Not many people do.
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Old 07-26-2016, 08:24 AM   #20
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I put 4.56 in my stock Dana 35 rear and Dana 30 front with 33" tires and never had an issue, but I also wasn't doing much off road at the time just daily driving. Didn't have to swap axles and did it my self in a morning (front and rear) with a little research, patience, and tools off eBay. When I did mine also did a complete seal and bearing replacement front and rear since I had it all apart and hard 100k on it.
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Old 08-15-2016, 05:20 PM
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I put 4.56 in my stock Dana 35 rear and Dana 30 front with 33" tires and never had an issue, but I also wasn't doing much off road at the time just daily driving. Didn't have to swap axles and did it my self in a morning (front and rear) with a little research, patience, and tools off eBay. When I did mine also did a complete seal and bearing replacement front and rear since I had it all apart and hard 100k on it.
What kind of lockers did you have or recommend and their price?
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Old 08-15-2016, 09:32 PM   #22
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I changed the gears in my jeep myself after reading a lot about it and getting an understanding of it. I would recommend doing it yourself to gain knowledge and tools and save money. You just need a cheap harbor freight dial indicator and stand, micrometer, a big dead blow hammer, and a beam type inch pound torque wrench and patients. A lot of people are afraid of doing it but it's really not that big of a deal. I did take my axles completely out of my jeep and set them on jack stands to make it easier.
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Old 08-15-2016, 11:38 PM
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I changed the gears in my jeep myself after reading a lot about it and getting an understanding of it. I would recommend doing it yourself to gain knowledge and tools and save money. You just need a cheap harbor freight dial indicator and stand, micrometer, a big dead blow hammer, and a beam type inch pound torque wrench and patients. A lot of people are afraid of doing it but it's really not that big of a deal. I did take my axles completely out of my jeep and set them on jack stands to make it easier.
Alright so which carriers did you end up with, I got stock 3.07 and need new carriers to regear.
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Old 08-16-2016, 02:42 AM   #24
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Alright so which carriers did you end up with, I got stock 3.07 and need new carriers to regear.
Well i was out of money at the time i actually blew my spider gears out and cracked the carrier racing a S10 that forced me to do the gear swap lol.

I ended up going with a standard carrier for 4.11 gears and a lockright. I knew a guy that set up gears and he told me that genuine Spicer gears set up easier than "other brands" so that's what i went with. I set the gears up an obscene amount like 17 times i think. Just playing with different shims and checking gear marking compound patterns until i got the hang of it and settled on one i thought looked good.

When it came to do the front i felt confident in my gear set up ability's since i already had the rear under my belt and it all went smooth. So for the front i went a little cheaper on gears and bought Yukon. And the guy that told me Spicer set up easier was right. Yukon gears did seem to change gear marking compound in a few different parts and it made it a little harder to settle on a pattern. But eventually i did and it took me way less tries than the first time. I never had a problem out of the Yukons even though the machining was not quite as precise and concentric as the Spicers. If i were to set up gears again i would have no problem setting Yukons up but Spicer is a better quality product.

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