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4.56 or 4.88 gears?

Jerry Bransford

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According to the internet 🙄 cherokee 4spd is best option with a 4th.
That opinion isn't held by many any more. It only used to be a popular swap. It's longer so you need to make the rear driveshaft even shorter, it runs significantly hotter, and the wiring is difficult because of all the wiring color changes over the years with the AW4. I helped during an AW4 conversion years ago and we (mrblaine and I) had trouble with the wire color changes that didn't match wiring instructions found on various webpages like Stu's. I wouldn't touch an AW4 now.
 

mrblaine

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That opinion isn't held by many any more. It only used to be a popular swap. It's longer so you need to make the rear driveshaft even shorter, it runs significantly hotter, and the wiring is difficult because of all the wiring color changes over the years with the AW4. I helped during an AW4 conversion years ago and we (mrblaine and I) had trouble with the wire color changes that didn't match wiring instructions found on various webpages like Stu's. I wouldn't touch an AW4 now.
Once you apply a bit of critical thought to the wiring, it gets much easier. Essentially all but about 5-6 of the wires are just connecting what is on the two plugs to the 26 pin connector by color. After that, there are a couple of grounds, 12v+ in run position, 12V+ constant, TPS tap, and brake sense tap.

There was also not much thought given to how to actually unplug stuff if needed. We changed a bunch of that around to put the various inputs on the correct side of the plugs.

We can do the wiring in our sleep, we won't but we can.
 
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bitbyte

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Go with the thick version of the 5.13 gears so they will fit your Rubicon locker cases. The below is from my install.

View attachment 310975
Jerry. (or anyone else with firsthand experience)

I purchased this exact same kit from Revolution for my 06LJR. They didn't come with crush sleeves although when I ordered them they said they did. The sales guy called around to a number of his associates that deal with TImken etc and according to them they don't need a crush sleeve.

My mechanic who worked for Chrysler for 25 years and has done tons of rear ends (but never 5.38 thick gears or anything from Revolution) said he's never had one they didn't need a crush sleeve for.

Did yours need a crush sleeve?
 

machoheadgames

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Jerry. (or anyone else with firsthand experience)

I purchased this exact same kit from Revolution for my 06LJR. They didn't come with crush sleeves although when I ordered them they said they did. The sales guy called around to a number of his associates that deal with TImken etc and according to them they don't need a crush sleeve.

My mechanic who worked for Chrysler for 25 years and has done tons of rear ends (but never 5.38 thick gears or anything from Revolution) said he's never had one they didn't need a crush sleeve for.

Did yours need a crush sleeve?
It’s based on the axle model & design. TJ Dana 44’s use shims for pinion preload. Is the 25 year guy familiar with the difference from TJ to JK? JK D44s use crush sleeves. Maybe he’s thinking of those. The TJ Dana 35 and the front low pinion Dana 30 use crush sleeves for pinion preload.
 
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Jerry Bransford

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Jerry. (or anyone else with firsthand experience)

I purchased this exact same kit from Revolution for my 06LJR. They didn't come with crush sleeves although when I ordered them they said they did. The sales guy called around to a number of his associates that deal with TImken etc and according to them they don't need a crush sleeve.

My mechanic who worked for Chrysler for 25 years and has done tons of rear ends (but never 5.38 thick gears or anything from Revolution) said he's never had one they didn't need a crush sleeve for.

Did yours need a crush sleeve?
There are no crush sleeves in either Dana 44 under a TJ Rubicon. He's thinking of the Dana 30. And yes, the 5.38 thick gears are exactly what you need for the TJ Rubicon factory lockers.

This is what I installed into my TJ Rubicon.

Label 2.jpg
 

bitbyte

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It’s based on the axle model & design. TJ Dana 44’s use shims for pinion preload. Is the 25 year guy familiar with the difference from TJ to JK? JK D44s use crush sleeves. Maybe he’s thinking of those. The TJ Dana 35 and the front low pinion Dana 30 use crush sleeves for pinion preload.
Thanks macho. I passed it along to my mechanics. They actually worked at Chrysler for 30 or 40 years but left in early 2000s so I'm guessing they may not have done any TJs.

Thanks to both you and Jerry for the info.
 
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