USA Standard Replacement Ring & Pinion Gear Set For Dana 44 in a 5.38 Ratio
A 5.38 ring and pinion is what you reach for when a Dana 44 has to turn 37 in. or larger tires, crawl rocks with a manual transmission, or get a heavy, low-geared classic truck moving again. The USA Standard Gear ZG D44-538 is a new replacement gear set for the standard-rotation Dana 44: an 8.50 in. ring gear, a 26-spline pinion and 10 ring gear bolts. It suits the Dana 44 rears under 1997-2006 Wrangler TJ and 1986-1993 Cherokee XJ models, and the standard-rotation Dana 44 fronts and rears found in early Blazer, K-series, Bronco, Scout, Wagoneer and Dodge W-series trucks.
The pinion gear turns 5.38 times for every turn of the ring gear and the axle shafts. That multiplication is how you get back the torque a taller tire takes away: going from a 31 in. tire to a 37 in. tire makes the original gears act roughly 19 percent taller, so engine rpm falls at cruise and the truck labors on every grade. A deeper ratio brings rpm back up into the engine's power band and makes low-speed control better off road. Because the pinion gets larger as the ratio gets deeper, Dana splits the 44 into carrier series. A 5.38 set fits the 4-series carrier used for 3.92 and numerically higher ratios. If your axle has 3.73 or lower gears now, it has a 3-series carrier and needs either a new carrier or a thick gear made to space the ring gear over.
First confirm what you have. Read the axle tag on a cover bolt or count teeth and divide ring by pinion; our guide to finding your axle gear ratio walks through it. Then run the numbers for your tire and cruise speed using the regear guide for bigger tires so you know 5.38 is the right ratio and not 4.88. If the axle is noisy, pull the cover, wipe the teeth and look for spalling, and check the pinion for in-and-out play. The Dana 44 problems and rebuild cost guide covers the usual failure points.
The gear maker lists this set for standard-rotation Dana 44 axles, including 1997-2006 Wrangler TJ and 1986-1993 Cherokee XJ rears, 1986-1992 Comanche, 1971-1977 Bronco fronts, 1971-1980 Scout II, Wagoneer and Grand Wagoneer, Chevy and GMC K10/K20 and K5 Blazer fronts through 1980, and 1994-2001 Ram 1500 and 1994-2002 Ram 2500 fronts. It does not fit reverse-rotation (high-pinion) fronts, the Dana 44 used in JK or JL Wranglers, or the larger Dana 44HD. Many older axles were built in several versions, so match the axle tag and rotation, or send us your year and VIN and we will check it. Pair it with a 3.92-and-up carrier such as the Yukon Dana 44 3.92+ open carrier; if you would rather keep a 3-series carrier, the Revolution thick 5.38 Dana 44 set is the version made for that. More Dana 44 parts are in our hard parts section.
Gears do not include bearings. Plan on new pinion and carrier bearings, a crush sleeve, pinion seal and shims, such as the Dana 44 carrier installation kit plus pinion bearings. Published setup values for the standard Dana 44 are a 0.042 in. starting pinion shim, 14-19 in-lb of pinion bearing preload, 0.006-0.010 in. backlash, ring gear bolts at 55 or 75 ft-lb depending on bolt size, and bearing caps at 60 ft-lb. Paint the teeth and read the pattern on both drive and coast sides before you button it up; our backlash and pinion depth guide shows what a good pattern looks like. Fill with 75W-90 or 75W-140 gear oil, adding friction modifier if the axle has a clutch-type limited slip such as a Dura Grip for 3.92-and-up gears. Break the set in gently and change the oil at about 500 miles, as laid out in our ring and pinion break-in procedure.
| Brand | Yukon Gear & Axle |
| Part number | ZG D44-538 |
| Fits | USA Standard Replacement Ring & Pinion Gear Set For Dana 44 in a 5.38 Ratio |
| Type | Final Drive Gears |
| Condition | New |
| Ships | Same business day (in stock), from the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
Yes, the gear maker lists the 1997-2006 Wrangler Dana 44 rear. You also need a 4-series carrier (3.92 and up). If your TJ came with 3.73 or lower gears, its carrier is the wrong series and must be replaced or you need a thick gear set instead.
No. This is a standard-rotation set. High-pinion (reverse-rotation) Dana 44 fronts need a reverse-cut gear set. Look at where the pinion enters the housing, or send us your year and VIN.
New pinion and carrier bearings, a crush sleeve, pinion seal, shims and new ring gear bolts. Reusing old bearings is not a good idea because they are damaged when pressed off and are the usual cause of noise after a regear.
It depends on the engine, transmission and how you drive, but 5.38 is usually chosen for 37 in. or larger tires, or for crawling with a manual transmission. Run your tire size and cruise rpm through a gear calculator before you order.
Yes. On a four-wheel-drive vehicle the front and rear ratios must match, or the transfer case and driveline will bind in 4WD. Order a matching 5.38 set for the other axle.
A quality 75W-90 or 75W-140 gear oil. Add friction modifier if the axle has a clutch-type limited slip. Change it after the first 500 miles to flush out break-in wear material.
