Yukon Gear Master Rebuild Kit for Jeep Wrangler JL Dana 44 / 220mm Rear
A howl from behind the back seat that comes in on the gas and changes on coast, a rear pinion seal that weeps gear oil down the housing, or a re-gear that never went quiet are the usual reasons a Wrangler JL owner ends up shopping for this part. This is the Yukon Gear & Axle Master Overhaul Kit, part number YK D44JL-REAR, made for the 220mm Dana 44 rear axle in the JL. Yukon builds it around Timken bearings and races with seals and the small parts a rear center section needs, so the carrier and pinion go back together on all-new bearings in one job.
The 220mm figure is the ring gear diameter, and it is how the rear axle is told apart from the 210mm Dana 44 up front. In the rear housing the pinion is driven by the rear driveshaft and turns the ring gear on the carrier, which sits on two side bearings. The pinion bearings carry the thrust of every launch and every tow, and they have to hold a set preload or the gear mesh drifts. The carrier bearings fix backlash. When either set wears, the contact pattern on the ring gear walks off center and the gears start to whine well before anything breaks. Unlike the front axle on the JK and JL, which runs a reverse-cut gear set, the rear is a standard-rotation Dana 44, so the gear pattern is read the conventional way. An overhaul kit renews the bearing races and cones and the seals together, which is what lets you reset the axle to a true preload instead of mixing worn and fresh parts.
Start at the yoke: with the driveshaft off, push and pull the pinion and try to lift it. Any end play means the pinion bearings have lost preload. Spin the yoke by hand and feel for roughness. Then pull the fill plug, or the cover if you can, and look at the oil and the gear teeth. Gray metallic oil is normal; flakes, a chipped tooth, or spalling on a bearing roller means it is time for the kit. If the noise is a hum at one constant speed that changes when you swerve, check the axle shaft bearings and tires first, since those get mistaken for gear noise. If you are digging into the rest of the drivetrain at the same time, our Wrangler JK and JL service guide lays out what to check on the transmission and transfer case side.
This kit is listed for the Jeep Wrangler JL Dana 44 220mm rear. Every JL Rubicon has the Dana 44 out back. Sport and Sahara models were built with either the newer-design Dana 35 or the Dana 44 in the rear, so a non-Rubicon JL may or may not take this kit. Read the axle tag on the housing tube or check the build sheet before you order, and if you are not sure, send us your year and VIN and we will confirm it. Gladiator JT trucks also use a new-design Dana 44 rear, but this kit is catalogued for the JL, so check with us before ordering for a JT. Front axle work is covered by the matching Yukon JL Dana 44 210mm front master kit, and other overhaul sets are in our rebuild kit category.
Before teardown, measure and write down backlash at several points on the ring gear and paint a contact pattern. That tells you whether the old setup was right and gives you a target if you reuse the gears. Pull the axle shafts, then mark the bearing caps so they go back on the same side. Press the old cups out and the new Timken cups in until they bottom fully. Set pinion depth with shims, set pinion bearing preload with an inch-pound torque wrench, then install the carrier and set backlash and side bearing preload with the carrier shims. A clamshell carrier bearing puller pulls the old side bearings without damaging the carrier, and a Dana 44 carrier shim driver seats the outer shims cleanly. Confirm the pattern with marking compound before the cover goes on.
If you plan to add a locker while the carrier is out, an Eaton ELocker for JL and JT Dana 44 goes in during the same setup. Refill with the gear oil grade your owner's manual lists, usually 75W-90 or 75W-140, and add friction modifier only if your axle has a clutch-type limited slip. Break new bearings and any new gears in with easy driving and no towing for the first few hundred miles, then change the oil.
| Brand | Yukon Gear & Axle |
| Part number | YK D44JL-REAR |
| Fits | Yukon Gear Master Rebuild Kit for Jeep Wrangler JL Dana 44 / 220mm Rear |
| Type | Differential Overhaul Kits |
| 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.
Only if that Jeep has the Dana 44 rear. JL Sport and Sahara models came with either a Dana 35 or a Dana 44 rear. The Rubicon always has the Dana 44. Check the axle tag or send us your VIN to confirm.
This kit is for the 220mm Dana 44 rear. The front kit is for the 210mm Dana 44 front axle on the JL Rubicon, which uses a reverse-cut gear set. The bearings and seals are different, so order the kit for the end you are rebuilding.
Yukon builds its master overhaul kits with Timken bearings and races, along with seals and small parts for the application.
Yes, as long as the teeth are not pitted, chipped or scored. Measure backlash and record the contact pattern before teardown so you can set the used gears back where they wore in.
Use the grade your owner's manual specifies, usually 75W-90 or 75W-140. Add friction modifier only for a clutch-type limited slip. Change the oil again after the break-in miles.
