Regearing

[MarkAllan]

I have a regearing question that I'm open to suggestions and answers. I just bought another TJ (because one is never enough) and this one is a 2002 4.0L 5spd with dana 30 front and dana 35 on the back (LSD) . The stock gearing is 3.07. I'm going to be lifting it by 3.25 inches and putting on 33's. What gear ratio would best suit a general mix of driving conditions like city driving and moderate trail driving. For the most part this will be my daughters Jeep so it's likely to be more the pavement princess. Open to your suggestions Thanks!!

 

[JMT]

4.88

 

[MarkAllan]

4.88

Thanks JMT. I was thinking 4.10 because I wouldn't have to switch out the carriers but I now think that might be worthwhile to get into the 4.56 - 4.88 range. Or I swap out to the Dana 44's...chu-ching

 

[MikeE024]

Thanks JMT. I was thinking 4.10 because I wouldn't have to switch out the carriers but I now think that might be worthwhile to get into the 4.56 - 4.88 range. Or I swap out to the Dana 44's...chu-ching

Regarding axle housing upgrades, you can run the Dana 30 in the front since you aren’t looking to run 5.38s. Less chi-ching problems, and you’ll be just fine up to 35s (just like the front Dana 44).

If you are ever set on swapping the front, I recommend going with a HP30 over the low pinion Dana 44 (since you won’t need 5.38s with the manual).

 

[MarkAllan]

Regarding axle housing upgrades, you can run the Dana 30 in the front since you aren’t looking to run 5.38s. Less chi-ching problems, and you’ll be just fine up to 35s (just like the front Dana 44).

If you are ever set on swapping the front, I recommend going with a HP30 over the low pinion Dana 44.

Excellent insight and advice...thanks MikeE024!

 

[JMT]

Thanks JMT. I was thinking 4.10 because I wouldn't have to switch out the carriers but I now think that might be worthwhile to get into the 4.56 - 4.88 range. Or I swap out to the Dana 44's...chu-ching

The Dana 30/35 combines more than up to the task of 33’s. The 4.0 makes power at a higher rpm than most cars.

They’re very happy at 3000rpm at 70mph.

488

513 looks better

 

[MarkAllan]

The Dana 30/35 combines more than up to the task of 33’s. The 4.0 makes power at a higher rpm than most cars.

They’re very happy at 3000rpm at 70mph.

488
View attachment 670709
513 looks better
View attachment 670710

So if I run 4.88's do I have to change my stock carriers?

 

[JMT]

So if I run 4.88's do I have to change my stock carriers?

The carrier break in a Dana 30 is 3.73, so if you go to 3.73 or higher you need a new carrier or thick cut gears.

 

[MarkAllan]

The carrier break in a Dana 30 is 3.73, so if you go to 3.73 or higher you need a new carrier or thick cut gears.

Got it...I'm a bit of a newbie to diffs and gearing. I get the basics of it but what I lack in knowledge I make up for in enthusiasm ha-ha Thanks for your help!!

 

[JMT]

Got it...I'm a bit of a newbie to diffs and gearing. I get the basics of it but what I lack in knowledge I make up for in enthusiasm ha-ha Thanks for your help!!

You got this! You’re not too far away from me. I’m in E Wa. The auto transmission that I swapped into my rig came out of Vancouver B.C. Pretty cool.

 

[MarkAllan]

You got this! You’re not too far away from me. I’m in E Wa. The auto transmission that I swapped into my rig came out of Vancouver B.C. Pretty cool.

Nice!! And thanks for the vote of confidence . There are a lot of TJ's up here but you need to cherry pick because we have a lot of frame rust...80% have issues.

 

[JMT]

Nice!! And thanks for the vote of confidence . There are a lot of TJ's up here but you need to cherry pick because we have a lot of frame rust...80% have issues.

Rust is the devil. Good luck with the regear. Some good folks around here if you’re doing it yourself.

 

[jjvw]

488 for 33s/5 speed