Jeep Wrangler TJ Full Electric Conversions

1999 TJ re-gear to 4.56

Turboloft

Turboloft

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Sep 18, 2023
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Location
Kentucky
Hey all,

I am finally getting around to regearing and doing some differential work on my 1999 TJ with a 4.0 and 5-speed manual transmission. I am keeping both Dana 30 and 35 (Running 33' tires and no locker in rear).

My main question is where is the best place to supply a ring gear and pinion gear kit for both diffs, all bearings and seals, and a new carrier for front and rear. Im also interested in building a super 35, but unsure of where to supply parts at a decent price.

Secondly, is the AMC 35 and Dana 35 ring gear and carriers the same? I know the axles are bolt on for the AMC but wanna make sure everything else is the same prior to buying.

Product suggestions and tips would be GREATLY appreciated!
 
Revolution Gear.

I'd recommend 4.88s for 33s.

I did a super 30 and 35 with Eaton E-lockers on my 97. I did 4.88s for 35s and should have done 5.13s.

-Mac
 
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4.88 will make 33s drivable with the 5 speed.
 
Turboloft said:
Hey all,

I am finally getting around to regearing and doing some differential work on my 1999 TJ with a 4.0 and 5-speed manual transmission. I am keeping both Dana 30 and 35 (Running 33' tires and no locker in rear).

My main question is where is the best place to supply a ring gear and pinion gear kit for both diffs, all bearings and seals, and a new carrier for front and rear. Im also interested in building a super 35, but unsure of where to supply parts at a decent price.

Secondly, is the AMC 35 and Dana 35 ring gear and carriers the same? I know the axles are bolt on for the AMC but wanna make sure everything else is the same prior to buying.

Product suggestions and tips would be GREATLY appreciated!
Click to expand...
So here are my options then...
ITEM​
LINK​
PRICE​
OX Locker​
$1,362​
Yukon 30 and 35 Gear kit w/ front carrier​
$609​
Right Chromoly Axle​
$245​
Left Chromoly Axle​
$245​
​
​
$2,461​
OR​
ITEM​
LINK​
PRICE​
Yukon 30 and 35 Gear kit w/ carriers​
$704​
Front Aussie Locker​
$300​
​
​
​
​
​
​
​
​
$1,004​

For the new axles, are bearings and seals gonna be different? Am I missing anything or is this about right for what I need to be getting?
 
The one thing I can't figure out is how you can run 4340 chromoly in the rear, with the current bearing setup. The alloy has to be 1541H to use the Dana 35 axle bearings. 4340 is for the Dana 44.

Is there an additional conversion I'm missing?
 
xXDavidCXx said:
The one thing I can't figure out is how you can run 4340 chromoly in the rear, with the current bearing setup. The alloy has to be 1541H to use the Dana 35 axle bearings. 4340 is for the Dana 44.

Is there an additional conversion I'm missing?
Click to expand...

You can. There are many examples of people running cromoly shafts in a Dana 35 where the bearings have worn into the shaft.
 
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I don't think many of us are running Ox. I have one on my wife's JK.

Ox uses a specific diff cover with a protrusion that activates the fork for the locker. Very similar to the TJ clutch.

The nice thing about that mechanism is you can actuate it four different ways...Ox sells mechanical levers, air and electric solenoids and a drive home screw in piece that activates the locker no matter what.

The downside to that protrusion is it hits everything in a TJ. Track bars. Drag link. Gas tank.

Highly recommend Revolution gear and Eaton E-lockers.

-Mac
 
macleanflood said:
I don't think many of us are running Ox. I have one on my wife's JK.

Ox uses a specific diff cover with a protrusion that activates the fork for the locker. Very similar to the TJ clutch.

The nice thing about that mechanism is you can actuate it four different ways...Ox sells mechanical levers, air and electric solenoids and a drive home screw in piece that activates the locker no matter what.

The downside to that protrusion is it hits everything in a TJ. Track bars. Drag link. Gas tank.

Highly recommend Revolution gear and Eaton E-lockers.

-Mac
Click to expand...

Wow I didn't even think about that... these are the things they don't tell you huh. Thanks!
 
For what it’s worth, I run 2500 rpm at 65mph with 4.56’s, ax15 and Maxxis Razr MT 33x10.5’s. 4.88’s will put you ~300 rpm higher.

My recommendation is to buy gears from Revolution, Spicer seals from Rock Auto or Denny’s and shim kits from ECGS/Yukon Denny’s. I stay away from the Yukon or house brand seals in many master kits. Revolution shims are a PITA.

I am running elockers F/R and have had zero issues. They no longer sell rebuild kits for their units, but Barney from Eaton will take care of you if needed.
 
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for probably the same money you could go with an eaton truetrac or e-locker in the rear and not have the issues of the OX locker cable and cover. Also a much simpler install, especially in the case of the truetrac

You don't want chromoly axles in a Dana 35, as others have mentioned, they don't work with bearings riding directly on the shaft, the 1541 manganese steel @xXDavidCXx linked are what you want.
 
lumberjacklloyd said:
They no longer sell rebuild kits for their units, but Barney from Eaton will take care of you if needed.
Click to expand...

How big a deal is the "no rebuild kit" long term? Does anyone ever need to rebuild them?
What about the ARB? Same question- do folks ever have to rebuild them and are parts available?
 
Last edited:
MtPockets said:
How big a deal is the "no rebuild kit" long term? Does anyone ever need to rebuild them?
What about the ARB? Same question- do folks ever have to rebuild them and are parts available?
Click to expand...


Eaton used to sell the coil magnet, spider gears, locking ring all as rebuild or part kits. They did not sell many and finally phased them out. Users either had no issues or the carrier was toast at the time of rebuild.

My locking ring showed wear on the teeth that engage side gear after 50k miles. The side gear dogs and engagement channel in the carrier were near perfect, so they sent out a locking ring from their engineering facility for free via 2 day.

I really can’t complain. The only thing they don’t like is cold 85w-140.
 
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MtPockets said:
...
What about the ARB? Same question- do folks ever have to rebuild them and are parts available?
Click to expand...

I have at least 60k miles on my ARBs with no need to rebuild anything. The carrier bearings will last as long as any other carrier. The air seals are not leaking. Parts are available.
 
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The only thing you'll need to replace is the coil, which they call a stator, and only then if you mess something up in the install or on the trail (like ripping the wires out) or engage the locker going 70 down the highway, which will break the tangs off the stator.

When i bought my lockers, the Dana 44 one showed up with broken tangs on the stator due to packaging, and the Dana 30 i bought locally and had some surface rust, so i replaced both stators with new kits from eaton, which come with the stator, bearing races and a new thrust bearing for the locker.

Looks like Jegs and Summit list the Dana 30 and Dana 44 stator service kits.
 
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Strizzo said:
for probably the same money you could go with an eaton truetrac or e-locker in the rear and not have the issues of the OX locker cable and cover. Also a much simpler install, especially in the case of the truetrac

You don't want chromoly axles in a Dana 35, as others have mentioned, they don't work with bearings riding directly on the shaft, the 1541 manganese steel @xXDavidCXx linked are what you want.
Click to expand...

So even a Eaton E-locker sold with Nitro axles that are chromoly are no dice? That's interesting to me...
 

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