Dana 44 gear install instructions? - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 9 Old 02-18-2012, 09:51 AM Thread Starter
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Dana 44 gear install instructions?

I am finally ready to try a gear installation in my Rubicon. I will be installing 5:38's in a ProRock 44 and Stock rear end.
I read an old thread that referenced a install guide on Poly's website but I cannot find it. Does anyone have a guide that covers a D44 specific diff?
Thanks.
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post #2 of 9 Old 02-18-2012, 01:13 PM
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Here you go:
http://www.polyperformance.com/instr...REAR-GEARS.pdf

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post #3 of 9 Old 02-18-2012, 08:43 PM
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Good instructions. The case spreader is expensive but a great aid in getting a long lasting gear setup.
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post #4 of 9 Old 02-18-2012, 10:31 PM
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That's a great write up with pics from Polly. Is this going to be your first gear setup?

08 2Door Red Rubicon. Rock Krawler 5.5 Longarm Coilover, Polly rear Coilovers. AEV hood & wheels, 37"KM2s, JE Reel 1350 shafts, 5.38 Yukon gears, Superior axles, Shrockworks stubby, Fab Fours rear, sPod, Rebel Offroad brakes, Warn winch and lots more.

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post #5 of 9 Old 02-18-2012, 11:17 PM
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I would try finding a pro to do the install. That's a lot of money to risk.

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post #6 of 9 Old 02-19-2012, 11:28 AM Thread Starter
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This is going to be my first gear install. My local 4x4 shop sends the regear jobs to the local Jeep dealership. The mechanic told me he charges 5 hours labor at $70/hour per axle (not sure what the 4x4 shop fee is to farm it out).
I figure it would be worth the risk to at least try it once on the front end. I can sell the tools I have accumulated for this job if I really f'it up. If I can get it to work out, I have a friend or two that made it clear that I could practice on theirs too! I enjoy tinkering on this Jeep. It would irk me to let this job slide without making an attempt.

Welding, on the otherhand, is not a skill that I have mastered yet (only learned on exhausts) so that is something I still ask my friends to do.

I did not even think to click on tech on Poly's site. I was looking under the parts section. Thanks for pointing me in the right direction.
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post #7 of 9 Old 02-19-2012, 11:47 AM
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Good luck. Let us know how it turns out!

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post #8 of 9 Old 01-05-2014, 04:37 AM
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Originally Posted by Fixerupper View Post
This is going to be my first gear install. My local 4x4 shop sends the regear jobs to the local Jeep dealership. The mechanic told me he charges 5 hours labor at $70/hour per axle (not sure what the 4x4 shop fee is to farm it out).
I figure it would be worth the risk to at least try it once on the front end. I can sell the tools I have accumulated for this job if I really f'it up. If I can get it to work out, I have a friend or two that made it clear that I could practice on theirs too! I enjoy tinkering on this Jeep. It would irk me to let this job slide without making an attempt.

Welding, on the otherhand, is not a skill that I have mastered yet (only learned on exhausts) so that is something I still ask my friends to do.

I did not even think to click on tech on Poly's site. I was looking under the parts section. Thanks for pointing me in the right direction.
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Good luck. Let us know how it turns out!
So how did this turnout?

JKUR auto | 5:38 | tires 36"x17 wheels 9"x4.5"bs | TF 6"| ASFIR bumpers, skids | SuperWinch EPi9.5 | RCV shafts | SC traildash | Xenon fenders | OBA York

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post #9 of 9 Old 01-09-2014, 02:33 PM Thread Starter
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It turned out well so far (only have 4000 miles on the new gears). I am waiting on a set of chromoly rear axle shafts before I tear down the differentials to see how they are wearing in. No major problems yet but I do have a hum at 40 mph that is barely audible over the 37 inch MTR-K's. I will be checking the pinions first.
I have re-geared my buddys JK and he wheels a lot harder than I do. With 40's he has had no issues yet either.

The most helpful item was the home-made setup pinion bearing. I spend a long time grinding and sanding the old bearing til it come on and off with very light taps of a mallet.
Another thing that helped out is using the cell phone to document the pattern with each change in shims. Its a helluva lot easier to see the subtle changes when you look at the pics one after the other.
The case spreader was helpful in not having to pry out the components every time (and to preload the carrier shims).
A 4 foot breaker bar made crushing the sleeve relatively easy despite my 160 pounds of force hanging on the end of it (actually overcrushed the first sleeve).
It was within budget to buy the el-cheapo 20 ton Harbor Freight press too!

It was a great project overall. I used Yukon gears in mine and gears supplied by Rough Country in my buddy's.
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