Gear difference on Dana 44?

[Angio4x4]

Good evening and sorry once again for the inconvenience, but reading the forum I can't understand this difference. Talking to another Tj owner tonight, he told me he had a new and never used 4.10 bevel gear for Dana 44 that he could give me because he didn't fit his Dana 44 on his Tj. He has a 2006 Tj 2.4 65th with rear Dana 44 and front Dana 30 whose original ratios were 3.73. He explained to me that the gears of his Dana 44 had to have a higher crown to be able to mount in his axle and that the standard ones were not adequate. The bevel gears in question are the following in the photo, how can I know if they will fit in my rear Dana 44? What changes in the axes to have a difference in size in the gears? Is it a valid product to mount the G2?

PS: mine is a 2006 sport Dana 44-Dana 30

 

[jjvw]

What is the tire size and which transmission does the Jeep have?

Are you familiar with the tedious process of installing axle gears?

 

[Angio4x4]

What is the tire size and which transmission does the Jeep have?

Are you familiar with the tedious process of installing axle gears?

Thank you for your prompt reply, my Tj currently has 265/75/16 and I don't know if I will ever be able to go up to 285/75/16 because of the laws that prevent us from fitting larger tires. Unfortunately, we are aware of the fact that the assembly process is long and difficult, in fact the closest garage that knows how to mount these gears is located about 300km from me. But how do I know if those gears will fit into my Dana 44? In its axis it was not possible to install them due to different dimensions !!!

 

[Vinman]

Are you sure your friends jeep has a Dana 44? Typically the 4 cylinder TJ’s only came with the rear Dana 35. Also, that part number should fit the non-Rubicon Dana 44 that should be in your Jeep. That being said, If your TJ has the stock 3.73’s that all North American non-Rubicon TJ’s came with, it wouldn’t make enough of a difference in gear ratio to warrant a change. If your TJ has the Dana 44 with 3.07’s like the Australian jeeps had it would be worth it.
Oh yeah, the easiest way to confirm if your friends Jeep has the rear Dana 44 axle is the style of the fill plug, metal screw in plug is 44 and a rubber push in plug is the Dana 35

 

[4speedhandler]

so based on a preliminary search of G2 gear's website it should fit if you have the proper carrier. sounds like he tried to install the 4.09 gear onto the 3.73 carrier. If your carrier/posi/locker (whatever you wanna call it) is for a 3.92 and numerically higher gear then it will fit, if the carrier is for 3.73 or numerically lower gears then it wont fit. figure out what gears you currently have and it will tell you what you need to do to swap. if it is the 2006 sport with the manual trans it should have 3.73 gears and would then necessitate a new carrier for those gears, im not sure what the automatics had for gears.

 

[Vinman]

Doh! Forgot all about the differences between the carriers.

 

[Vinman]

Ok, after re-reading the original post where your friend is referring to a higher crown required, he is saying he needs “thick” cut gears like the Rubicon’s came with. Either that or he has to change the carrier to the 3.92 and higher numerically carrier. I’m still skeptical on whether his Jeep came with a Dana 44 with the 2.4 engine.

 

[Angio4x4]

What would the "carrier" be? how can I know which one I need? Unfortunately I was not able to watch his Jeep, but apparently, from 2004 to 2006 all imported i.tjs had the Dana 44 in the rear. Both his and my Jeep have 6-speed manual transmission. As for the difference, I believe that 4.56 would be very short with 265/75/16 while with 4.10 I could be much closer to the original configuration and recover a gear in everyday driving. Mine now have a 3.73.

 

[Alex0413]

He's referring to "thick cut" gears - so you can mount 4.11 on a 3.73 down Dana 44 carrier like the Rubicons come with.

 

[Angio4x4]

Perfect, I hope I understand something. In practice, it may be necessary to replace the differential with a new one in order to install the 4.10? . If I don't get it wrong, there are differentials that start from the bottom, 3.07 for example, and can go up to 3.73 without being able to go to 4.10, while others start at 3.73 and can go higher. How can I understand if the bevel gears will mount without having to replace it, can I measure or check something to understand it? I apologize for the difficulty, but here, there are only a lot of confused and unclear news about the components to buy / replace to make the re gear.

 

[Angio4x4]

Could these be the components to replace in order to mount the 4.10 on my Differential?

http://www.4x4proyect.com/ricambi/g2-axle-35-2033-kit-completo-di-installazione-differenziale/it

 

[Alex0413]

A "thick cut" gear is a numerically high gear (3.92+) that is designed to fit on the smaller (3.73-) carriers. For example, my 2004 Rubicon came with thick cut 4.11 gears mounted to the smaller 3.73- carrier. Therefore if you have a Dana 44 with the factory 3.73- carrier, a thick cut 4.11 will fit perfectly.

 

[Jerry Bransford]

Carriers are the same size whether they're for high or low ratio gears. The only difference in carriers meant for low or high ratios is where it positions the ring gear in relation to the pinion gear. Closer to or further away from the pinion gear to compensate for the pinion gear's diameter. A smaller diameter for lower ratios and larger diameter for higher ratios.

 

[Angio4x4]

Good evening guys. Today I managed to get under my Tj and I carefully cleaned the plates of my two axes. I think I discovered something fantastic, if I'm not wrong, I think I have 3.07 gear mounted. So, everything is different from what I imagined before, I think that by mounting at 4.10 my Tj will be another. Now I understand why I always had 100 rpm difference on the online calculation of engine revs / speed. So if I have 3.07, everything changes, right? Below are the photos of the plates and serial numbers printed on the axle covers.

Dana 30

Dana 44

Unfortunately, they had told me that all the imported TJ 2004-2006 were imported with gear 3.73 and having believed in this, I had never thoroughly verified this news with my own hands. So, I apologize for the initial turmoil that I created in this topic.

 

[Alex0413]

3.07 - 3.73 gears share the same carriers. So a thick up 4.11 will indeed fit. But I don't think a Dana 44 came in 3.07.. you sure you have a Dana 44? Have a pic of the diff cover?

 

[Vinman]

But I don't think a Dana 44 came in 3.07..

I know for sure the TJ’s destined for Australia were indeed offered with 3.07 gears.

 

[Alex0413]

I know for sure the TJ’s destined for Australia were indeed offered with 3.07 gears.

TJ's with Dana 35 were, but did the Dana 44 in Australia come with 3.07 too? They didn't in the states

 

[Vinman]

TJ's with Dana 35 were, but did the Dana 44 in Australia come with 3.07 too? They didn't in the states

Yes, all TJ’s exported to Australia were equipped with the rear 44, I’m not 100% positive but I seem to remember they all had 3.07’s too.

 

[Alex0413]

Yes, all TJ’s exported to Australia were equipped with the rear 44, I’m not 100% positive but I seem to remember they all had 3.07’s too.

That's interesting, I learn something new everyday!

 

[Angio4x4]

Hi guys, last night I didn't take a picture of the pear on my bridge, but I got one taken the first day I bought the Tj. The shape of the differential case is square and the loading cap is metallic.

3.07 - 3.73 gears share the same carriers. So a thick up 4.11 will indeed fit. But I don't think a Dana 44 came in 3.07.. you sure you have a Dana 44? Have a pic of the diff cover?

Perfect, I saw this kit in spain that could be right for me, should it fit without problems? I can get the rear gear out of the kit because my friend would give it to me, "the one posted at the top" and let me leave only the assembly kit.
http://www.4x4proyect.com/ricambi/g2-axle-kjtj2410-kit-corona-e-pignone/it