Information Gathering For Re-Gear

[jboswell11]

This summer I plan to re-gear to 5.38 and have been doing research on the proper parts to order prior to the build. My front axle is easy peasy, stock Rubicon Dana 44 (Or D34 as some call it) so that is straight forward, RG&A 5.38 R&P with master install kit.

The rear is where it gets interesting, I have a G2 Dana 44 with 33 spline shafts and a Detroit locker. Reading on G2's website and I see them bragging about "latest gen" Dana 44 design with larger pinion and ring gear. So, I give them a call (actually get a person on the phone quite quickly), explain my situation and the guy tells me "oh yeah we have always built them the Core 44 for the TJ with the JK style bigger ring gear and pinion". I say "so, I can just order a JK gearset and master install kit for the rear and be fine" he says yes, I thank him and hang up.

I dont know anything about JKs so I assume only one gear size is available... of course not. Now I see JK rubicon, non-rubicon, conflicting information about if the non-rubicons had the larger ring gear...etc

I put another call into G2 but could not get through, sent them another message... but, I was wondering if anyone on the forum has re-geared a G2 axle for our TJs and can confirm what R&P and install kit I need to purchase. Or possibly if there is an easy way to tell for sure what I have without pulling the rear carrier and pinion out for a measurement. Thanks!

 

[AndyG]

Message @Rob5589 , he's a good dude , been into more rear ends than Liberace.

 

[taylormade73]

Message @Rob5589 , he's a good dude , been into more rear ends than Liberace.

Funniest thing I read all week.

 

[Rob5589]

Message @Rob5589 , he's a good dude , been into more rear ends than Liberace.

You sick bastard

I was out waaaay before the JK. But, the JK, as I have read, is a slightly larger ring gear and pinion bearings than a standard 44. The G2 cat probably knows what he is talking about, so I'd follow his recommendation.

Now, gotta run. More rear ends to get in to...

 

[Fouledplugs]

Does your G2 rear end have a serial number? It should be stamped into the housing. I would be surprised if they did not do this on all their builds.

Once you have the serial and share it with G2, G2 should be able to look up all the specs on it and confirm which gear set you actually need.

But, if that doesnt pan out, I would pull it for yourself to confirm. The last thing you want to do is go back and fourth buying and returning parts in the mail.

 

[DrDmoney]

Why not just buy the R&P from G2

 

[jboswell11]

Thanks for the help guys! Darn tag fell off the plate or that's the route I would go..

Seems like most of the G2 gears for sale aren't really advertised as replacements for their axles.. But I can call them again and ask, makes sense that they would sell packages to regear their own. I really wanted RG&A stuff though..

 

[DrDmoney]

The Rear Core 44’s have the JK 8.8” ring gear, a larger pinion shaft and bearings if that helps.

 

[jboswell11]

The Rear Core 44’s have the JK 8.8” ring gear, a larger pinion shaft and bearings if that helps.

That does help! Thank you!

 

[jboswell11]

@DrDmoney or anyone else that may know do I need the differential master overhaul kit for the JK rubicon or non-rubicon?

From my research so far I have found the JK Rubicon (TruLok) Dana 44 has different carrier bearings, cross pin offset, and axle lengths as compared to the JK non-rubicon (non TruLok) Dana 44.

Because my G2 axle has a 33 spline Detroit locker I think it is 99% that the "regular" or non Rubicon master overhaul kit is the one I need because I don't see that Eaton makes a Detroit locker in 33 spline that would replace a trulok.

Just to confirm I sent another email to G2 and will call them when they open Monday.

 

[DrDmoney]

@DrDmoney or anyone else that may know do I need the differential master overhaul kit for the JK rubicon or non-rubicon?

From my research so far I have found the JK Rubicon (TruLok) Dana 44 has different carrier bearings, cross pin offset, and axle lengths as compared to the JK non-rubicon (non TruLok) Dana 44.

Because my G2 axle has a 33 spline Detroit locker I think it is 99% that the "regular" or non Rubicon master overhaul kit is the one I need because I don't see that Eaton makes a Detroit locker in 33 spline that would replace a trulok.

Just to confirm I sent another email to G2 and will call them when they open Monday.

Are you thinking the 35 spline G2 uses a larger 8.8” RG and the 33 spline uses the 8.5”? Everything I ever read on the Core 44’s was they all used the larger one in rear applications. I did read that on the internet though. I run the 35 spline G2 assembly in the rear of my TJ and the HP Core 44 in the front. Maybe it would be wise to nail them down on which one they use or if it’s a proprietary RG design.

 

[jboswell11]

Are you thinking the 35 spline G2 uses a larger 8.8” RG and the 33 spline uses the 8.5”? Everything I ever read on the Core 44’s was they all used the larger one in rear applications. I did read that on the internet though. I run the 35 spline G2 assembly in the rear of my TJ and the HP Core 44 in the front. Maybe it would be wise to nail them down on which one they use or if it’s a proprietary RG design.

No, I think G2 uses the bigger (JK) ring gear and (JK) pinon for all the core 44 axles they build (that's what G2 told me and has been confirmed by several others).

It would be pretty clear cut what master install kit was needed but the problem is that JK axles that have the trulock (commonly referred to as Rubicon Dana 44 but was also offered as an option in non Rubicon JK) or not have different sized carrier bearings.

The only reason I mention that my current G2 axle has 33 spline shafts and a Detroit locker is because I think that tells me that the G2 axle housing setup must be like a non-trulock JK because a 33 spline Detroit is not available for the JK trulock housing... only the JK non trulock.

I am going to confirm with G2 tomorrow anyway... and will report back to close the thread for search fodder should anyone have this question in the future.

 

[DrDmoney]

No, I think G2 uses the bigger (JK) ring gear and (JK) pinon for all the core 44 axles they build (that's what G2 told me and has been confirmed by several others).

It would be pretty clear cut what master install kit was needed but the problem is that JK axles that have the trulock (commonly referred to as Rubicon Dana 44 but was also offered as an option in non Rubicon JK) or not have different sized carrier bearings.

The only reason I mention that my current G2 axle has 33 spline shafts and a Detroit locker is because I think that tells me that the G2 axle housing setup must be like a non-trulock JK because a 33 spline Detroit is not available for the JK trulock housing... only the JK non trulock.

I am going to confirm with G2 tomorrow anyway... and will report back to close the thread for search fodder should anyone have this question in the future.

It would be good to know this as others will undoubtedly ask the same question.

 

[jboswell11]

Alright, glad I called G2 again... almost screwed up ordering.

My G2 rear is NOT a core 44, it had the old cast aluminum cover so that made it their first generation axle which they called a Dana 44 (lol, real original), this axle was a copy of the TJ Rubicon Dana 44. The helpful gentleman at G2 looked up in their records and verified my version of the axle 33 spline Detroit was built with the 3.92 and up carrier so it takes regular (thin) gears unlike the Rubi axles that all require the thick ones due to the locker being of 3.73 and down deck height.

So what I need is regular old thin cut Dana 44 gears for the rear and a master rebuild kit for the Rubicon Dana 44 — Revolution Dana 44-538 and K35-2045 for the master install kit.

The front is Revolution Dana 44-538TD (thick gear for the stock rubi axle) and the same K35-2045 master install


I also asked just for information of others should they stumble upon this thread.... If a person has an actual Core 44 the D44JK-538 gears and 35-2053 master install kit would be correct for the rear. It does indeed use the JK 8.8" gear and larger pinion as well as the non Rubicon JK master install kit.

 

[DrDmoney]

Alright, glad I called G2 again... almost screwed up ordering.

My G2 rear is NOT a core 44, it had the old cast aluminum cover so that made it their first generation axle which they called a Dana 44 (lol, real original), this axle was a copy of the TJ Rubicon Dana 44. The helpful gentleman at G2 looked up in their records and verified my version of the axle 33 spline Detroit was built with the 3.92 and up carrier so it takes regular (thin) gears unlike the Rubi axles that all require the thick ones due to the locker being of 3.73 and down deck height.

So what I need is regular old thin cut Dana 44 gears for the rear and a master rebuild kit for the Rubicon Dana 44 — Revolution Dana 44-538 and K35-2045 for the master install kit.

The front is Revolution Dana 44-538TD (thick gear for the stock rubi axle) and the same K35-2045 master install


I also asked just for information of others should they stumble upon this thread.... If a person has an actual Core 44 the D44JK-538 gears and 35-2053 master install kit would be correct for the rear. It does indeed use the JK 8.8" gear and larger pinion as well as the non Rubicon JK master install kit.

Glad you followed up on this, it’s good info for G2 owners that want to re-gear, also I hope you’re running at least a 35” tire with the 5.38 gears.

 

[jboswell11]

Glad you followed up on this, it’s good info for G2 owners that want to re-gear, also I hope you’re running at least a 35” tire with the 5.38 gears.

absolutely! 35's and the 42rle... hoping to get my OD back!

 

[Jerry Bransford]

Glad you followed up on this, it’s good info for G2 owners that want to re-gear, also I hope you’re running at least a 35” tire with the 5.38 gears.

5.38 is even better with 33's when you have the 42RLE as the OP does. I could use slightly more rpms with my 42RLE and 35's even with my 5.38 gearing.

 

[Fonz54]

Message @Rob5589 , he's a good dude , been into more rear ends than Liberace.

Shit I was reading this while on a conference call for work and I busted out laughing!