I had a 5.38 Revolution gear and pinion put in, about 3 years ago (so it's outside of the warranty!). After some grinding noise that went along with the rotation of the wheels, I popped the rear diff cover to find a lot of metal in there. I put the cover back on, took it to a different shop than the one that installed the gear and had them look to make sure everything was installed properly, it was. They're telling this is what happens when you put a 5.38 in a Dana 44. They're recommending that I drop down to a 4.88 and change the TCase.
It's an 05 tj rubi with 70,000 miles on it. There are maybe 15,000 miles on the new gears. I've wheeled it maybe twice with the new gears. I mostly wheel in rocks, cause that's what Colorado has. It's on 37 tires. The Dana 44 is original. The first time I heard the noise was on the street, not the trails, so I don't believe the pinion was damaged on the trail (dunno).
My questions are:
1) Did I just get unlucky and I should replace the 5.38 with another 5.38?
2) I live and wheel in Colorado, wouldn't 4.88 be too high? My biggest issue is that I have a manual & I'm attempting to not burn up the clutch in the rocks.
3) Is it worth replacing the TCase?
4) Do you agree with going down to a 4.88 & swapping the TCase or should I do something different? Suggestions appreciated!
Thank you in advance!
It's an 05 tj rubi with 70,000 miles on it. There are maybe 15,000 miles on the new gears. I've wheeled it maybe twice with the new gears. I mostly wheel in rocks, cause that's what Colorado has. It's on 37 tires. The Dana 44 is original. The first time I heard the noise was on the street, not the trails, so I don't believe the pinion was damaged on the trail (dunno).
My questions are:
1) Did I just get unlucky and I should replace the 5.38 with another 5.38?
2) I live and wheel in Colorado, wouldn't 4.88 be too high? My biggest issue is that I have a manual & I'm attempting to not burn up the clutch in the rocks.
3) Is it worth replacing the TCase?
4) Do you agree with going down to a 4.88 & swapping the TCase or should I do something different? Suggestions appreciated!
Thank you in advance!