Revolution Gear & Axle 07-18 Jeep Wrangler JK Rubicon Dana 44 Front Ring & Pinion Master...

If you are regearing a 2007-2018 Jeep Wrangler JK Rubicon for 35 or 37 inch tires, or chasing a front-end howl that shows up when the transfer case is in 4WD or rises with speed even in 2WD, the front Dana 44 needs a full set of bearings and hardware. The Revolution Gear and Axle 35-2051 is the Timken-bearing master install kit made for the JK Rubicon front Dana 44, and it is the part to order alongside new front gears.

What the master install kit does in a JK Rubicon front Dana 44

The Rubicon front axle is a reverse-rotation Dana 44 with a factory selectable locker. Because it is a front axle with a high-pinion layout, the gears are cut to drive on the side that suits forward travel at the front of the Jeep, and the pinion bearings carry load in a way that leaves no room for a sloppy setup. The pinion rides on two tapered bearings loaded by a crush sleeve, the locker carrier rides on two side bearings, and shims set depth and position. Revolution lists this kit with Timken pinion and carrier bearings, pinion seal, crush sleeve, pinion shims, carrier shims, ring gear bolts, cover gasket or silicone, and axle seals. That last item matters on a JK front: the inner tube seals often get disturbed when the shafts come out, and leaking seals let gear oil into the knuckles.

Symptoms that point to front bearings or a regear

• A whine or howl from the front that changes on and off throttle, or is loudest when the front is driving in 4WD
• Pinion yoke play or a pinion seal leak that keeps coming back
• Gear oil seeping past the inner axle seals toward the knuckles
• Sluggish highway pull and constant downshifts after moving up in tire size on factory 4.10 gears
• Any front locker service or gear swap, where used bearings and shims should not be reused

How to confirm before ordering

Confirm it really is a Rubicon front: the tag on the housing and the factory locker switch tell you, and a non-Rubicon JK has a Dana 30 up front that takes a different kit. Check the yoke for play, look at the oil for glitter, and note the factory ratio, which on a Rubicon is usually 4.10. Our JK regear kit buyer's guide lays out which gears and kits each JK axle needs, and the Dana 44 problems and rebuild cost guide covers noise diagnosis.

Fitment

Revolution lists 35-2051 for the 2007-2018 Jeep Wrangler JK Rubicon with the Dana 44 front axle differential. It does not fit the JK Sport or Sahara Dana 30 front, the JK rear axles, or the 2018-up JL and JT Dana 44 fronts. If a used Jeep has had an axle swap, read the housing tag or send us the year and VIN. For the rear of the same Jeep, use the JK Rubicon rear Dana 44 master install kit, and more parts are in our rebuild kits category.

Install notes

For new front gears, the Revolution JK Rubicon front 4.88 set is the common 35 inch tire choice and the 4.56 front set suits 33s; match the same ratio in the rear. The factory 4.10 locker carrier already sits on the deep-gear side, so the gears go onto your existing locker. Revolution's D44JK setup chart lists a 0.042 inch starting pinion shim, 22-35 in-lb pinion bearing preload with new bearings, 0.006-0.010 inch backlash, 75 or 135 ft-lb ring gear bolts depending on bolt size, and 80 ft-lb bearing caps. Many builders swap the crush sleeve for a JK front crush sleeve eliminator to make preload easier to hit. Set depth from the contact pattern using our backlash and pinion depth guide, keep the locker wiring clear when the carrier goes back in, fill with 75W-90 gear oil, and follow the break-in procedure. After a ratio change, reprogram the JK's tire size and axle ratio so the speedometer and shifting stay correct.

Does this kit fit a non-Rubicon JK front axle?

No. Non-Rubicon JKs (Sport, Sahara and similar trims) have a Dana 30 front axle that takes a different kit. 35-2051 is for the JK Rubicon Dana 44 front.

What comes in the Revolution 35-2051 kit?

Revolution lists Timken pinion and carrier bearings, pinion seal, crush sleeve, pinion shims, carrier shims, ring gear bolts, cover gasket or silicone, and axle seals.

Do I need a new carrier to run 4.56 or 4.88 gears on a Rubicon?

Usually not. A Rubicon that left the factory with 4.10 gears already has a locker carrier on the deep-gear side of the carrier break, so 4.56, 4.88 and deeper gears bolt to it. Confirm your original ratio on the axle tag.

Will this kit work on a 2018 or newer JL Rubicon?

No. The JL and JT use a different Dana 44 front with its own install kit. This kit is for the 2007-2018 JK Rubicon front.

What gear oil goes in the JK Rubicon front axle?

75W-90 gear oil. After new gears, change it early once the break-in miles are done to flush out wear material.

Should I replace the rear kit at the same time?

If you are regearing, yes. Both axles must run the same ratio, and the rear Dana 44 on a Rubicon uses its own master install kit.