I've been doing a lot of thinking about this because it's my next big mod. I just have to keep er road friendly, so totally flat is probably off the table for me. If I can gain 2-3" of clearance with a tuck, and still keep everything happy, I'll consider that a win for me.
You can get 0.75" more happiness if you up your Rokmen BL to a Savvy! ;)
 
This morning I removed the carrier in the Dana 44 and found this on my pinion gear.
44B95A26-9C46-4B4F-AC5E-DFB60AD76D10.jpeg

Bummer. So I texted the guy I bought the axle from this picture. He texted me back and said, “that’s messed up now I feel bad. I didn’t know it was like that. Let me come up with a solution.” So he asked me what gears I wanted to run. I said, ultimately 4.56. He said, what if you get the gears and I come to your house and regear the front and rear for you?” So, we agreed and that’s the plan. He said “I’m sorry about that. I don’t do business that way. A lot of people would just say, too bad. But I want you to be happy.”
 
Nice gesture, and will save you a bunch of coin.
Yeah, a ton of coin. I really wish I had the money for a locker right now. I could wait till January to have him come up and do it. I might have the coin then for the locker too. Maybe just put a lunchbox in the front and call it good for now.
 
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I was in the same boat as you when I re-geared. Wanted to put a front locker in, but just didn't have the coin at the time, so meh.
 
This morning I removed the carrier in the Dana 44 and found this on my pinion gear.
View attachment 48175
Bummer. So I texted the guy I bought the axle from this picture. He texted me back and said, “that’s messed up now I feel bad. I didn’t know it was like that. Let me come up with a solution.” So he asked me what gears I wanted to run. I said, ultimately 4.56. He said, what if you get the gears and I come to your house and regear the front and rear for you?” So, we agreed and that’s the plan. He said “I’m sorry about that. I don’t do business that way. A lot of people would just say, too bad. But I want you to be happy.”
Wow! An honest mechanic !! I have a feeling this is gonna turn out really sweeeet for you @JMT
 
This morning I removed the carrier in the Dana 44 and found this on my pinion gear.
View attachment 48175
Bummer. So I texted the guy I bought the axle from this picture. He texted me back and said, “that’s messed up now I feel bad. I didn’t know it was like that. Let me come up with a solution.” So he asked me what gears I wanted to run. I said, ultimately 4.56. He said, what if you get the gears and I come to your house and regear the front and rear for you?” So, we agreed and that’s the plan. He said “I’m sorry about that. I don’t do business that way. A lot of people would just say, too bad. But I want you to be happy.”

That is a sweet deal! You are going to love the 4:56 with those tires!!
 
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Wow! An honest mechanic !! I have a feeling this is gonna turn out really sweeeet for you @JMT
I hope so. The guy is really nice to be doing this. And I’ve seen his gear setups. The pattern looks perfect. So, it’s not exactly how I wanted to spend my last $4-500 this year on the Jeep, but it will save me so much $$$ how can I resist? 4.56 baby! A good split between 33’s and 35’s. I’ll be slightly overgeared for 33’s and slightly under for 35’s if I ever go big.
 
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That is a sweet deal! You are going to love the 4:56 with those tires!!
Can you believe it? I really didn’t know what to expect. I thought he might just get me a new pinion and install the rear. But he knows enough to know that’s not worth it and just go all the way now. Not sure when we can get this in. We’ll need a good day or two, maybe split weekends. He’ll have to come up with his tools from about 80 miles out. I told him I’d bring it to him, but he said he doesn’t have any place to work on it there. He lives in an RV park. So I’m going to buy his gas and food and beer. And I guess I”m going to learn a lot when he comes up.
 
That's what I did. Split it up between 2 weekends. Did the rear first and just removed the front drive shaft and ran rear wheel drive for a spell.
 
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Can you believe it? I really didn’t know what to expect. I thought he might just get me a new pinion and install the rear. But he knows enough to know that’s not worth it and just go all the way now. Not sure when we can get this in. We’ll need a good day or two, maybe split weekends. He’ll have to come up with his tools from about 80 miles out. I told him I’d bring it to him, but he said he doesn’t have any place to work on it there. He lives in an RV park. So I’m going to buy his gas and food and beer. And I guess I”m going to learn a lot when he comes up.
If it were cooler I'd drive down and help, or sit and watch. I love projects like this.. can't wait for future updates :)
 
Can you believe it? I really didn’t know what to expect. I thought he might just get me a new pinion and install the rear. But he knows enough to know that’s not worth it and just go all the way now. Not sure when we can get this in. We’ll need a good day or two, maybe split weekends. He’ll have to come up with his tools from about 80 miles out. I told him I’d bring it to him, but he said he doesn’t have any place to work on it there. He lives in an RV park. So I’m going to buy his gas and food and beer. And I guess I”m going to learn a lot when he comes up.

I know it sucks having to come up with the money unexpectedly, but in this case it isn't like you blew out your brakes and now you have to replace all of your calipers, rotors, pads, and lines only to have it drive the same 500 later, Or having to fix a blown clutch fro 600 bucks only to have it drive exactly the same.

At least now when it gets done you are going to notice it right of the bat leaving from a stop. It is going to brake a ton faster on the freeway too. It is going to be weird for a while on the freeway. I can't wait to do mine too, but I have to restrain myself. I am trying to get it done, and be able to put miles on it before I go to Moab. I know it is still a ways a way, but it is amazing how much time flies. Especially when the weather starts getting good in AZ. I almost wish I could do it right now, but money is tight and even worse my time right now.

Congrats. You are going to be happy when it is done.
 
Wait till you hit the trail. You'll think you swapped out your 231 for a 4.1 241 TC.
I’m so pumped. I didn’t think this would be possible before Moab. So, the prospect looks very promising. It’s so hot here now that I may go ahead and get the parts when I see them on sale and do it early Fall.

I’ve always been curious to see how she crawls with the 6-speed and 4.56 on 33’s. Should be slow, real slow.
 
When I went to Moab in May, 2016, I cut it really close. I re-geared in March, so I had to be sure they were broke in before driving 2000 miles, lol!
 
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@JMT, i know this has nothing to do with your build but have you ever considered D rings for your front bumper ? Not that your RED BEAST needs anything, of course.
I think 2 nickel D rings would look sharp against your black front bumper. Yes, no?
D rings are on my list, but toward the bottom.