Revolution Gear & Axle Dana 44 Thick Gear Rear Axle 4.10 Ratio Dual Drilled Ring & Pinion Set

The D44-410TD is for a specific and very common situation: you have a standard-rotation Dana 44 with a factory 3.73 or lower ratio, you have gone up a tire size or two, and the truck or Jeep now lugs in top gear. You want 4.10 gears, but you do not want to buy a new carrier or give up the limited slip or locker you already have. This new Revolution Gear & Axle 4.10 set uses a thick ring gear that bolts straight onto the 3.73-and-down carrier, and its dual-drilled bolt holes accept either size of ring gear bolt that Dana 44 carriers have used.

What a thick 4.10 gear does in a Dana 44

Dana 44 carriers come in two series. A deeper ratio uses a smaller pinion, so to keep the pinion and ring gear in mesh Dana moved the ring gear mounting flange on carriers built for 3.92 and numerically higher ratios. Revolution lists the carrier break for this set at 3.73/3.92. A normal 4.10 gear set is cut for the 3.92-and-up carrier. A thick gear adds material to the back of the ring gear so a 4.10 ratio sits in the right place on the earlier 3.73-and-down carrier. The published specs: 8.5 in. ring gear, 26-spline pinion, standard rotation, 10 x 3/8 in. and 7/16 in. ring gear bolt holes, 10-bolt cover, 8620 steel, made in Korea. Going from 3.73 to 4.10 is about a 10 percent drop in gearing, which roughly cancels a 10 percent taller tire.

Symptoms that call for a regear or new gears

• The engine drops out of its power band in overdrive and the transmission hunts between gears on the highway
• Slow, labored starts and climbs after a tire upgrade, and higher transmission temperatures when towing
• A whine that changes between throttle and coast, the classic Dana 44 sign of worn gears or pinion bearings
• Chipped, pitted or scored teeth found when the cover comes off

How to confirm what you need

Before ordering, confirm two things: the ratio you have now and the carrier series. Count the ring gear and pinion teeth or read the axle tag, and our carrier break explainer shows how the 3.73 and 3.92 carriers differ. If the noise is the reason you are in there, use the whine diagnosis guide to separate gear noise from bearing noise. Our Dana 44 problems and rebuild cost guide covers what else usually wears in this axle.

Fitment

Revolution's fitment table for its Dana 44 thick gear family lists rear Dana 44s in the 1997-2006 Jeep Wrangler, 1986-1993 Cherokee, 1986-1992 Comanche, Wagoneer and Grand Wagoneer, J10, CJ5, CJ6, CJ7 and Scrambler, 1971-1977 Ford Bronco, 1975-1980 K5 Blazer, and 1994-2002 Dodge Ram 1500 and 2500, among others. Not every one of those vehicles left the factory with a Dana 44 in the rear, and this is a standard-rotation gear, so it is not for high-pinion reverse-rotation front axles. The Jeep JK and JL rear 44s use their own gear sets. It only fits a 3.73-and-down carrier; if your carrier is the 3.92-and-up type, order the standard-thickness D44-410 set instead. Send us the year, VIN and axle tag and we will match it for you.

Install notes

• Plan on a full set of new bearings, a crush sleeve and a pinion seal from a complete Dana 44 install kit matched to your axle and spline count.
• If you are replacing the carrier too, stay with a 3.73-and-down unit such as the Yukon open carrier for 3.73-and-down, or step up to the Dura Grip limited slip in the same series.
• Set pinion depth, preload and backlash to spec and confirm with a tooth pattern before closing it up.
• Use 75W-90 or 75W-140 gear oil, with friction modifier for a clutch-type limited slip.
• Break the gears in gently: short drives with cool-downs, no towing at first, and an early oil change. See our break-in procedure.

Going deeper for 35s? Compare the 4.56 thick set, or browse more axle hard parts.

Will this 4.10 gear fit my stock 3.54 or 3.73 Dana 44 carrier?

Yes, that is what the thick ring gear is for. Revolution lists the carrier break at 3.73/3.92, and this set is made to mount on the 3.73-and-down carrier. It will not fit a carrier built for 3.92 and up.

What does dual drilled mean?

The ring gear is drilled and tapped for both 3/8 in. and 7/16 in. ring gear bolts, the two sizes Dana 44 carriers have used, so it bolts to either carrier style.

What tire size is 4.10 good for?

As a rough guide, 3.73 to 4.10 is about a 10 percent change, which matches roughly a 10 percent taller tire, for example going from about 30 in. to 33 in. Transmission, engine and use matter, so check with a gear ratio calculator or ask us.

Do I need a new install kit?

Yes. New gears should get new pinion and carrier bearings, a new crush sleeve, shims and a pinion seal. Old bearings are the usual reason a fresh regear starts whining.

Does it fit a Jeep JK or JL rear Dana 44?

No. The JK and JL rear Dana 44 axles use their own ring and pinion designs. Look for gear sets made for those axles.