Baystate Jeepers

I've had several TJR experts suggest that running stock D44 axles on 35's is doable provided you don't push them hard at full articulation and/or at the steering stops. Also, keep bouncing to a min. They will hold up fine if you wheel this way. Since my TJR only has 35K easy miles, I'm going to run what I got for now and focus on armor. Thanks again for all the advice.

5.38 on a Dana 44 is going to make the ring and pinion a weak link. And you don’t want to be replacing those on the trail. Your “fuse” should be something easy to replace. For me, it’s the warn hub. I could have got stronger hubs, but if something is going to give, I’d rather it was a hub. Two minutes to swap and the spare takes up no room.

I think I would stick with 4.88 if you are only going to 35s. Just my 2c.

Experts lol

To get down to the 5.38 ratio without making the pinion gear smaller than what it is with the 5.13 gears, Revolution Gear adjusted the tooth count on the ring gear but not the pinion so the pinion is still an 8 tooth pinion. RG claims they are every bit as strong as any of their other lower ratio gear sets.

I'm interested in Warn hubs at some point as well.

Revolution first released the 5.38 Rubicon "thick" gear sets on 10/29/15, so they have been on the market for awhile.
Tooth Count:

4.88 - 8 pinion, 39 ring gear
5.13 - 8 pinion, 41 ring gear
5.38 - 8 pinion, 43 ring gear

Photo of 5.38 pinion on left, 4.88 pinion on right

Gearing will be ok on highway but you will be throwing it into neutral a lot in 4 wheel low to stop.

Vanco big brake should address that issue.

Liv2Ryd wrote: ↑Mon Jun 22, 2020 4:04 pm 4.88 - 8 pinion, 39 ring gear
5.13 - 8 pinion, 41 ring gear
5.38 - 8 pinion, 43 ring gear

The pinion will be probably as strong. But the ring will be a bit (10%) weaker because the teeth are smaller. I’ve see teeth let go before the pinion. Rubicon d44 is not a rigid housing which also adds to the risk a bit because it can mess up the mating surfaces under flex which puts the teeth under more stress.

I’ll probably be fine if you don’t go bigger than 35 and don’t beat on it to badly. Almost nothing comes for free, everything has trade offs.

The Vanco kit is awesome. I can lock up all 4 wheels with 35s. Are you upgrading the master cylinder as well?

I'm starting with the brake kit only. These Jeeps can empty a wallet faster than my wife with a new credit card.

Liv2Ryd wrote: ↑Tue Jun 23, 2020 10:20 am I'm starting with the brake kit only. These Jeeps can empty a wallet faster than my wife with a new credit card.

Wallet? What wallet, I haven't seen one of those since I bought it...

BlackKnight wrote: ↑Wed Jun 24, 2020 4:12 pm

Liv2Ryd wrote: ↑Tue Jun 23, 2020 10:20 am I'm starting with the brake kit only. These Jeeps can empty a wallet faster than my wife with a new credit card.

Wallet? What wallet, I haven't seen one of those since I bought it...

Didnt you use it as a gear shim due to thickness of it?

Beem married for 15 years now, Jeep is only 7, has been thin for a LONG time LOL...

Stop going shopping at the mall. Get permission and lets go wheelin . Thats what you bought it for . FjR68

Got a killer deal on a set RCV shafts for my D44 TJR. I'm looking to possibly do the install myself. Any tips/tricks I should be aware of before jumping in? The kit came with the template for machining the knuckles to gain the required clearance.

Hardest part is taking knuckles apart to get them in, depending how rusty and seized up things are. Have plenty of Kroil (or whatever penetrant) and a torch handy