1. Smile Gear Swap 2005 TJ Unlimited

    I'm planning a gear swap in my 2005 TJ Unlimited from 3:73's to 4:56's. I already have the gears but still need bearings and shims etc... Anyway, I have never rebuilt an axle before. I know the importance of cleanliness and accuracy and am mechanically inclined, but I can't find any info on my year of Jeep. The nazis haven't released a book for it yet. I don't want to buy the factory book set. Just wondering if someone could e-mail me an exploited view and directions for rebuilding my axles. The front is a dana35 (I know...sigh), and the rear is a Dana 44 HD. Thanks, I know I'm reaching.

  2. #2

    Re: Gear Swap 2005 TJ Unlimited

    ADJUSTMENTS(Front Axle)
    Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are etched/marked onto each gear (PINION GEAR ID NUMBERS). A plus (+) number, minus (–) number or zero (0) is etched/marked on the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched/marked with a (0). The standard setting from the center line of the ring gear to the back face of the pinion is 92.08 mm (3.625 in.). The standard depth provides the best gear tooth contact pattern.

    Compensation for pinion depth variance is achieved with a select shim/oil slinger. The shims are placed between the rear pinion bearing and the pinion gear head (SHIM LOCATIONS).

    If a new gear set is being installed, note the depth variance etched into both the original and replacement pinion. Add or subtract this number from the thickness of the original depth shim/oil slinger to compensate for the difference in the depth variances. Refer to the Pinion Gear Depth Variance chart.

    Note where Old and New Pinion Marking columns intersect. Intersecting figure represents plus or minus the amount needed.

    Note the etched number on the face of the pinion gear head (–1, –2, 0, +1, +2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shims. If the number is positive, subtract that value from the thickness of the depth shim. If the number is 0 no change is necessary.

    PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance
    –4 –3 –2 –1 0 +1 +2 +3 +4
    +4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
    +3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 –0.001
    +2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 –0.001 –0.002
    +1 +0.005 +0.004 +0.003 +0.002 +0.001 0 –0.001 –0.002 –0.003
    0 +0.004 +0.003 +0.002 +0.001 0 –0.001 –0.002 –0.003 –0.004
    –1 +0.003 +0.002 +0.001 0 –0.001 –0.002 –0.003 –0.004 –0.005
    –2 +0.002 +0.001 0 –0.001 –0.002 –0.003 –0.004 –0.005 –0.006
    –3 +0.001 0 –0.001 –0.002 –0.003 –0.004 –0.005 –0.006 –0.007
    –4 0 –0.001 –0.002 –0.003 –0.004 –0.005 –0.006 –0.007 –0.008


    PINION DEPTH MEASUREMENT AND ADJUSTMENT
    Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indicator C-3339 (PINION GEAR DEPTH GAUGE TOOLS).

    Assemble Pinion Height Block 6739, Pinion Block 6733 and rear pinion bearing onto Screw 6741 (PINION GEAR DEPTH GAUGE TOOLS).
    Insert assembled height gauge components, rear bearing and screw into the housing through pinion bearing cups (PINION HEIGHT BLOCK).
    Install front pinion bearing and Cone-nut 6740 hand tight.
    Place Arbor Disc 6732 on Arbor D-115-3 in position in axle housing side bearing cradles (GAUGE TOOLS IN HOUSING). Install differential bearing caps on arbor discs and tighten cap bolts to 41 N·m (30 ft. lbs.).
    NOTE: Arbor Discs 6732 has different step diameters to fit other axles. Choose proper step for axle being serviced.

    Assemble Dial Indicator C-3339 into Scooter Block D-115-2 and secure set screw.
    Position Scooter Block/Dial Indicator flush on the pinion height block. Hold scooter block and zero the dial indicator.
    Slowly slide the scooter block across the pinion height block over to the arbor (PINION DEPTH MEASUREMENT). Move the scooter block till the dial indicator probe crests the arbor and record the highest reading.
    Select a shim/oil baffle equal to the dial indicator reading plus the pinion depth variance number etched in the face of the pinion (PINION GEAR ID NUMBERS). For example, if the depth variance is –2, add +0.002 in. to the dial indicator reading.
    DIFFERENTIAL SIDE BEARING PRELOAD AND GEAR BACKLASH
    Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differential side bearing cones. The proper shim thickness can be determined using slip-fit Dummy Bearings D-348 in place of the differential side bearings and a Dial Indicator C-3339. Before proceeding with the differential bearing preload and gear backlash measurements, measure the pinion gear depth and prepare the pinion for installation. Establishing proper pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differential side play is measured, the pinion is installed, and the gear backlash shim thickness is measured. The overall shim thickness is the total of the dial indicator reading and the preload specification added together. The gear backlash measurement determines the thickness of the shim used on the ring gear side of the differential case. Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear side of the differential (SHIM LOCATIONS). Differential shim measurements are performed with spreader W-129-B removed.

    PRELOAD SHIM SELECTION
    NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary.

    Remove differential side bearings from differential case.
    Remove factory installed shims from differential case.
    Install ring gear on differential case and tighten bolts to specification.
    Install dummy side bearings D-348 on differential case.
    Install differential case in the housing.
    Install marked bearing caps in their correct positions. Install and snug the bolts (BEARING CAP BOLTS).
    With a dead-blow hammer, seat the differential dummy bearings to each side of the housing (SEAT DUMMY BEARINGS PINION SIDE) and (SEAT DUMMY BEARING RING GEAR SIDE).
    Thread Pilot Stud C-3288-B into rear cover bolt hole below ring gear (DIFFERENTIAL SIDE PLAY MEASUREMENT).
    Attach the Dial Indicator C-3339 to pilot stud. Position the dial indicator plunger on a flat surface between the ring gear bolt heads (DIFFERENTIAL SIDE PLAY MEASUREMENT).
    Push and hold differential case to pinion gear side of the housing and zero dial indicator (DIAL INDICATOR LOCATION).
    Push and hold differential case to ring gear side of the housing and record the dial indicator reading (READ DIAL INDICATOR).
    Add 0.008 in. (0.2 mm) to the zero end play total. This new total represents the thickness of shims to compress or preload the new bearings when the differential is installed.
    Rotate dial indicator out of the way on the pilot stud.
    Remove differential case and dummy bearings from the housing.
    Install the pinion gear in the housing. Install the pinion yoke and establish the correct pinion rotating torque.
    Install differential case and dummy bearings D-348 in the housing (without shims), install bearing caps and tighten bolts snug .
    Seat ring gear side dummy bearing (SEAT DUMMY BEARING RING GEAR SIDE).
    Position the dial indicator plunger on a flat surface between the ring gear bolt heads (DIFFERENTIAL SIDE PLAY MEASUREMENT).
    Push and hold differential case toward pinion gear and zero the dial indicator (ZERO DIAL INDICATOR).
    Push and hold differential case to ring gear side of the housing and record dial indicator reading (DIFFERENTIAL CASE RING GEAR SIDE).
    Subtract 0.05 mm (0.002 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash.
    Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing.
    Rotate dial indicator out of the way on pilot stud.
    Remove differential case and dummy bearings from the housing.
    Install the selected shims onto the differential case hubs.
    Install side bearings and cups on differential case.
    Install spreader W-129-B and adaters from Adapter Set 6987, onto housing. Spread the housing to receive differential case.
    Install differential case into the housing.
    Remove spreader from the housing.
    Install bearing caps and tighten bolts to 61 N·m (45 ft. lbs.).
    Rotate the differential case several times to seat the side bearings.
    Position the indicator plunger against a ring gear tooth (RING GEAR BACKLASH MEASUREMENT).
    Push and hold ring gear upward while not allowing the pinion gear to rotate.
    Zero dial indicator face to pointer.
    Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.12 mm - 0.20 mm (0.005 in. - 0.008 in.). If backlash is not within specifications transfer the necessary amount of shim thickness from one side of the housing to the other (BACKLASH SHIM).
    Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective.
    After the proper backlash is achieved, perform Gear Contact Pattern procedure.

    GEAR CONTACT PATTERN
    The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.

    The TOP LAND of the gear tooth is the top surface of the tooth. The PROFILE of the gear tooth is the depth of the tooth. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear is the portion of the tooth at the outer-end. The ROOT of the gear tooth is the lowest portion of the tooth (GEAR DESCRIPTION).

    NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered it is a 2 Axis cut gear.

    Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth.
    Wrap, twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern.
    With a boxed end wrench on the ring gear bolt, rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.
    The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeeze the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart (PATTERN INTERPRETATION (GEAR CUT 2 AXIS)) and (PATTERN INTERPRETATION (GEAR CUT 3 AXIS)) and adjust pinion depth and gear backlash as necessary.

    DIFFERENTIAL BEARING PRELOAD CHECK
    The final check on the differential assembly before installing the axles is torque to rotate pinion and differential combined. This will verify the correct differential bearing preload.

    Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.79-1.24 N·m (7-11 in. lbs.).
    Rear Axle:ADJUSTMENTS
    RING AND PINION GEAR
    Ring and pinion gears are supplied as matched sets only. The identifying numbers for the ring and pinion gear are etched into the face of each gear (PINION GEAR ID NUMBERS). A plus (+) number, minus (–) number or zero (0) is etched into the face of the pinion gear. This number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion etched with a (0). The standard depth provides the best teeth contact pattern. Refer to Backlash and Contact Pattern Analysis Paragraph in this section for additional information.

    Compensation for pinion depth variance is achieved with select shims. The shims are placed under the inner pinion bearing on the pinion shaft.

    If a new gear set is being installed, note the depth variance etched into both the original and replacement pinion gear. Add or subtract the thickness of the original depth shims to compensate for the difference in the depth variances. Refer to the Depth Variance charts.

    Note where Old and New Pinion Marking columns intersect. The intersecting figure represents plus or minus the amount needed.

    Note the etched number on the face of the drive pinion gear (–1, –2, 0, +1, +2, etc.). The numbers represent thousands of an inch deviation from the standard. If the number is negative, add that value to the required thickness of the depth shim(s). If the number is positive, subtract that value from the thickness of the depth shim(s). If the number is 0 no change is necessary. Refer to the Pinion Gear Depth Variance Chart.

    PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance
    –4 –3 –2 –1 0 +1 +2 +3 +4
    +4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
    +3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 –0.001
    +2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 –0.001 –0.002
    +1 +0.005 +0.004 +0.003 +0.002 +0.001 0 –0.001 –0.002 –0.003
    0 +0.004 +0.003 +0.002 +0.001 0 –0.001 –0.002 –0.003 –0.004
    –1 +0.003 +0.002 +0.001 0 –0.001 –0.002 –0.003 –0.004 –0.005
    –2 +0.002 +0.001 0 –0.001 –0.002 –0.003 –0.004 –0.005 –0.006
    –3 +0.001 0 –0.001 –0.002 –0.003 –0.004 –0.005 –0.006 –0.007
    –4 0 –0.001 –0.002 –0.003 –0.004 –0.005 –0.006 –0.007 –0.008


    PINION DEPTH MEASUREMENT AND ADJUSTMENT
    Measurements are taken with pinion cups and pinion bearings installed in housing. Take measurements with Pinion Gauge Set 6730 and Dial Indicator C-3339 (PINION DEPTH GAUGE TOOLS).

    Assemble Pinion Height Block 6739, Pinion Block 6734 and rear pinion bearing onto Screw 6741 (PINION DEPTH GAUGE TOOLS).
    Insert assembled height gauge components, rear bearing and screw into axle housing through pinion bearing cups (PINION HEIGHT BLOCK).
    Install front pinion bearing and Cone 6740 hand tight.
    Place Arbor Disc 6732 on Arbor D-115-3 in position in the housing side bearing cradles (GAUGE TOOLS IN HOUSING). Install differential bearing caps on Arbor Discs and tighten cap bolts to 41 N·m (30 ft. lbs.).
    NOTE: Arbor Discs 6732 have different step diameters to fit other axle sizes. Pick correct size step for axle being serviced.

    Assemble Dial Indicator C-3339 into Scooter Block D-115-2 and secure set screw.
    Place Scooter Block/Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion height block. Hold scooter block in place and zero the dial indicator face to the pointer. Tighten dial indicator face lock screw.
    Slowly slide the Scooter Block/Dial Indicator across the pinion height block over to the arbor bar (PINION DEPTH MEASUREMENT). Move the Scooter Block/Dial Indicator to the crest of the arbor bar and record the highest reading.
    Select a shim equal to the thickest dial indicator reading plus or minus the drive pinion gear depth variance number etched in the face of the pinion gear (PINION GEAR ID NUMBERS).
    Remove the pinion depth gauge components from the axle housing.
    PRELOAD SHIM SELECTION
    Differential side bearing preload and gear backlash is achieved by selective shims inserted between the bearing cups and the housing. The proper shim thickness can be determined using slip-fit dummy bearings D-345 in place of the differential side bearings and a dial indicator C-3339. Before proceeding with the differential bearing preload and gear backlash measurements, measure the pinion gear depth and prepare the pinion gear for installation. Establishing proper pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After the overall shim thickness to take up differential side play is measured, the pinion gear is installed, and the gear backlash shim thickness is measured. The overall shim thickness is the total of the dial indicator reading and the preload specification added together. The gear backlash measurement determines the thickness of the shim used on the ring gear side of the differential case. Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear side of the differential (ADJUSTMENT SHIM LOCATIONS).

    NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary.

    Remove differential side bearings from differential case.
    Remove factory installed shims from differential case.
    Install ring gear on differential case and tighten bolts to specification.
    Install dummy side bearings D-345 on differential case.
    Install differential case in axle housing (DIFFERENTIAL DUMMY BEARINGS).
    Install the marked bearing caps in their correct positions. Install and snug the bolts (BEARING CAP BOLTS).
    Using a dead-blow hammer seat the differential dummy bearings to each side of the housing (SEAT DUMMY BEARING PINION SIDE) and (SEAT DUMMY BEARING RING GEAR SIDE).
    Thread Pilot Stud C-3288-B into rear cover bolt hole below ring gear (DIFFERENTIAL SIDE PLAY MEASUREMENT).
    Attach a dial indicator C-3339 to Pilot Stud C-3288-B. Position the dial indicator plunger on a flat surface between the ring gear bolt heads (DIFFERENTIAL SIDE PLAY MEASUREMENT).
    Push and hold differential case to pinion gear side of the housing and zero dial indicator (ZERO DIAL INDICATOR).
    Push and hold differential case to ring gear side of the housing and record dial indicator reading (RECORD DIAL INDICATOR READING).
    Add dial indicator reading to the starting point shim thickness. This is the total shim thickness to achieve zero differential end play.
    Add 0.254 mm (0.010 in.) to the zero end play total. This new total represents the thickness of shims to compress, or preload the new bearings when the differential is installed.
    Rotate dial indicator out of the way on pilot stud.
    Remove differential case and dummy bearings from the housing.
    Install pinion gear in the housing. Install the pinion yoke and establish the correct pinion rotating torque.
    Install differential case and dummy bearings D-345 in the housing (without shims), install bearing caps and tighten bolts snug .
    Seat ring gear side dummy bearing (SEAT DUMMY BEARING RING GEAR SIDE).
    Position the dial indicator plunger on a flat surface between the ring gear bolt heads. (DIFFERENTIAL SIDE PLAY MEASUREMENT).
    Push and hold differential case toward the pinion gear and zero dial indicator (ZERO DIAL INDICATOR).
    Push and hold differential case to ring gear side of the housing and record dial indicator reading (RECORD DIAL INDICATOR READING).
    Subtract 0.05 mm (0.002 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears. This total is the thickness shim required to achieve proper backlash.
    Subtract the backlash shim thickness from the total preload shim thickness. The remainder is the shim thickness required on the pinion side of the housing.
    Rotate dial indicator out of the way on pilot stud.
    Remove differential case and dummy bearings from the housing.
    Install side bearing shims on differential case hubs.
    Install new side bearing cones and cups on differential case.
    Install spreader W-129-B on the housing and spread axle opening enough to receive differential case.
    Install differential case in the housing.
    Install differential bearing caps loosely.
    Remove spreader from the housing.
    Tighten bearing caps bolts to 108 N·m (80 ft. lbs.).
    Rotate the differential case several times to seat the side bearings.
    Position the indicator plunger against a ring gear tooth (RING GEAR BACKLASH MEASUREMENT).
    Push and hold ring gear upward while not allowing the pinion gear to rotate and zero dial indicator.
    Push and hold ring gear downward while not allowing the pinion gear to rotate. Dial indicator reading should be between 0.12 mm - 0.20 mm (0.005 in. - 0.008 in.). If backlash is not within specifications transfer the necessary amount of shim thickness from one side of the housing to the other (BACKLASH SHIM ADJUSTMENT).
    Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear. Readings should not vary more than 0.05 mm (0.002 in.). If readings vary more than specified, the ring gear or the differential case is defective.
    After the proper backlash is achieved, perform Gear Contact Pattern Analysis procedure.

    GEAR CONTACT PATTERN
    The ring gear and pinion teeth contact patterns will show if the pinion depth is correct in the housing. It will also show if the ring gear backlash has been adjusted correctly. The backlash can be adjusted within specifications to achieve desired tooth contact patterns.

    The TOP LAND of the gear tooth is the top surface of the tooth. The PROFILE of the gear tooth is the depth of the tooth. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear is the portion of the tooth at the outer-end. The ROOT of the gear tooth is the lowest portion of the tooth (GEAR DESCRIPTION).

    NOTE: If the PROFILE across the tooth is the same it is a 3 Axis cut gear. If the PROFILE across the tooth is tapered it is a 2 Axis cut gear.

    Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth.
    Wrap, twist, and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion. This will provide a more distinct contact pattern.
    Using a boxed end wrench on a ring gear bolt, Rotate the differential case one complete revolution in both directions while a load is being applied from shop towel.
    The areas on the ring gear teeth with the greatest degree of contact against the pinion teeth will squeegee the compound to the areas with the least amount of contact. Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart (PATTERN INTERPRETATION (GEAR CUT 2 AXIS)) and (PATTERN INTERPRETATION (GEAR CUT 3 AXIS)) and adjust pinion depth and gear backlash as necessary.

    DIFFERENTIAL BEARING PRELOAD CHECK
    The final check on the differential assembly before installing the axles is torque to rotate pinion and differential combined. This will verify the correct differential bearing preload.

    Torque to rotate the differential and pinion should be the torque to rotate the pinion plus 0.79-1.24 N·m (7-11 in. lbs.).
    I hope this helps you.

  3. #3

    Re: Gear Swap 2005 TJ Unlimited

    your front axle is a d30, and looks like there's some good info posted above^^.

    Most Dana axles are similar so you really don't need instructions specific to your jeep, any good gear setup guide would work.

  4. #4

    Re: Gear Swap 2005 TJ Unlimited

    Thank you SteelHeads, I'm sure I can work with that. Nice pic, it's the same color as mine. Hopefully I won't screw up now.

  5. #5
    Join Date
    Jan 2004
    Location
    Blacksburg/Williamsburg VA
    Posts
    2,573

    Re: Gear Swap 2005 TJ Unlimited

    Steel, where did you get that info? I've scoured the net looking for that and could never find it. Good stuff.
    06 VW (hardcore crawler)

    "The mountains are calling and I must go." -John Muir

  6. #6

    Re: Gear Swap 2005 TJ Unlimited

    Quote Originally Posted by currupt4130 View Post
    Steel, where did you get that info? I've scoured the net looking for that and could never find it. Good stuff.
    Either Randy's or JT Gear have a similar write up on their sites, not as detailed as that one though.

    Good Info.
    It used to be a jeep Thing,
    But all that stuff broke

    -Johnny-


  7. #7

    Re: Gear Swap 2005 TJ Unlimited

    Quote Originally Posted by jps4jeep View Post
    Either Randy's or JT Gear have a similar write up on their sites, not as detailed as that one though.

    Good Info.
    It was from a comment you made.

  8. Re: Gear Swap 2005 TJ Unlimited

    try this manual I found on line.
    Attached Thumbnails Attached Thumbnails Gear Swap 2005 TJ Unlimited-axsm-0053.pdf  


  9. Re: Gear Swap 2005 TJ Unlimited


  10. #10

    Re: Gear Swap 2005 TJ Unlimited

    Holy old post, Batman :P

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