The Blue Burro Gets New Gears 4.10 to 4.88 - Desert Jeep Rat
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The Blue Burro Gets New Gears 4.10 to 4.88

The Blue Burro Gets New Gears 4.10 to 4.88

I purchased some G2 Ring and Pinion Gears and Rebuild Kits to add new gears to my 09 Rubicon (The Blue Burro) from Jon at Bullpen Garage. I really wanted to do this install so I could see how it all worked and how it all went together. John advised me as to how difficult this install was going to be but did I listen, NO, I am an idiot that must suffer time and time again because I like to see how things work.

The multiple impression images(yellow on the rings) are about a third of how many I took and how many times I changed the shims to get it right.

As you can see in the second photo I had to get creative to hold the pinion in place while I torqued the crush rings down to what what felt like about 8 million foot pounds. I found this flex plate that someone had left behind on Charouleau Gap this spring and as usual I threw it in the back of the jeep and put in the garage pile when I got home. I knew I would use it for something eventually so a little cutoff and one hole drilled later I had a workable second set of hands to hold the pinion in lace to to allow for torque.

Once I had everything apart, I sent my Ring and Pinion out to have the old bearings pulled and new bearings pressed. I won’t mention that shop because it took them a week on a 2 day promise to remove the old bearings and press on the new ones. I scrapped the shop process because I eventually pulled and pressed the rear pinion 3 times after I got it home. I couldn’t wait 3 weeks to have it done by a shop so I purchased a Hobo Freight 12,000 lb press and a bearing pulling set. These were so easy to use! Who needs an unreliable shop!

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