Project Overview:

To compensate for the torque loss of my 33" tires, I needed to install new gears in my differentials.

Product Selection:

Product selection was really easy on this one. Since I ordered my lift from Rusty's Offroad, and they had a Dana 30 and Crystler 8.25" 4.56 kit, I just ordered it from them. They use Superior Axle and Gear ring and pinion sets exclusively. Superior is a reputable manufacturer, so I was happy. The kit also included all new bearings, gaskets and hardware.

Other Notes:

You'll need a ring carrier for the Dana 30 front differential. Rusty's had those available too.

Installation:

Since installing the gears takes some really specialized tools, and it's about 50% art and 50% science, I took it to one of my buddies at the local Jeep dealership to do.

Since the driveshaft was at such a steep angle, I knew I would need to put a bit more lube in to make sure the pinion got enough. I had my friend weld a nut to the inside of the pumpkin cover so more diff lube could be added.

As it turns out, even adding the extra lube wasn't enough. The pinion angle was so steep that the pinion bearings weren't getting any lube at all. Within a week, I completely fried the pinion bearings, heat welding them to the pinion. So, I had to remove the shims and get a new ring and pinion set for the rearend. I was really lucky that there was no damage to the pumpkin.

A very expensive lesson to learn. Hopefully somebody learns from my mistake. Even tough having your rear differential at a bit of an angle will cause some vibration and may lead to premature U-joint failure, I'd rather replace a $20 U-joint every 20,000 miles than have to replace a $500 ring and pinion set every week.