4.10 Re-gearing - 2025

Rene_05 · Friday at 1:12 PM

Tom (or someone on here) needs to start a side business of buying the gears directly from Dana and reboxing/reselling them to us, like Yukon

u2slow · Friday at 1:34 PM

Rene_05 said:
Amazon had let me place an order for them, but didn’t come into stock. Also placed orders at a few sites for the Yukons, but was let down when they didn’t actually have them. Since I’m going to pull the front myself now, I reckon I’ll have better luck. The shop hesitation is understandable I guess with having to more or less take the whole front end apart.

IFS diffs vary quite a bit in their construction. Some can be very finicky to setup right, so shops either shoot high, or try to not take the job. (Chevy ones come to mind because they split in half.) Our Liberty ones are really straightforward IMHO.

u2slow · Friday at 1:34 PM

Rene_05 said:
Tom (or someone on here) needs to start a side business of buying the gears directly from Dana and reboxing/reselling them to us, like Yukon

What happens if Dana has gone obsolete with this super 30 stuff?

2TALL1 · Friday at 1:51 PM

Exactly on the IFS a lot of the places I talked to especially the ones with high quotes act like they were like the clam shell style. Even after I reassured them it was like a normal Dana 30.
The fact they didn’t know also steered me away from them.
One guy quoted me $2,100 and when I told him I was going to be bringing the gears and master install kit he said it was going to be an extra $250 WTF…

u2slow · Friday at 2:06 PM

2TALL1 said:
The fact they didn’t know also steered me away from them.

Sign of the times. Shop are not in business to be well-read on every vehicle. Price it at a CYA level, and get on with the more predictable work for other customers.

Edit: they want/need their parts markup to make ends meet.

Rene_05 · Friday at 2:30 PM

u2slow said:
What happens if Dana has gone obsolete with this super 30 stuff?

I think we might already be there. Probably not enough demand to keep making them.

Rene_05 · Friday at 2:32 PM

u2slow said:
Sign of the times. Shop are not in business to be well-read on every vehicle. Price it at a CYA level, and get on with the more predictable work for other customers.

Edit: they want/need their parts markup to make ends meet.

A little perspective definitely helps with all this.

2TALL1 · Friday at 2:33 PM

Here’s another idea for you.
Get ahold of Yukon and see if they have a list of qualified installers in your area…

duderz7 · Saturday at 12:39 AM

When I did my calling around every place I spoke with wanted the rear axle to remain in the Jeep during rebuild. And that is how I did mine. There's no way I could have achieved the necessary torque on a bench. The front wasn't as bad, but I had to get on the bench too and sit on diff while I torqued down the crush sleeve.

JeepJeepster · Sunday at 8:55 AM

I honestly thought Dana quit making the 4.10 gears many years ago. Figured Yukon just bought up whatever was left. I have no plans of buying another Liberty, but many years ago, I for some reason bought two sets of 4.10's for the front diff.

duderz7 said:
When I did my calling around every place I spoke with wanted the rear axle to remain in the Jeep during rebuild. And that is how I did mine. There's no way I could have achieved the necessary torque on a bench. The front wasn't as bad, but I had to get on the bench too and sit on diff while I torqued down the crush sleeve.

You should take pics of stuff like that.

I think I clamped mine in a vice and torqued it down. Cant remember for sure though.

2TALL1 · Sunday at 12:06 PM

20 years ago I used to build square body Chevy pickups.
Frame off builds with custom lifts I had 2 places I took my axles to have built and they both had custom vices to hold the axles.( oh both places didn’t make it through fuqing covid scam)
Mine is a 6 speed so my carriers won’t work with the 4:10’s. Kinda why I bought an extra set plus the ease of having them built prior to doing my complete suspension rebuild.

duderz7 · Sunday at 2:09 PM

JeepJeepster said:
I honestly thought Dana quit making the 4.10 gears many years ago. Figured Yukon just bought up whatever was left. I have no plans of buying another Liberty, but many years ago, I for some reason bought two sets of 4.10's for the front diff.

You should take pics of stuff like that.

I think I clamped mine in a vice and torqued it down. Cant remember for sure though.

When you're doing it outside in an Idaho winter you don't take as many pictures as you should, but I do have a thread of my build on here somewhere.

2TALL1 · Sunday at 2:22 PM

Omg yes I followed your winter gear swap.
That had to have been brutal.
Maybe in my younger years…lol
By the way Rene_05 that is a darn good looking jeep.
I hope mine turns out half as nice!!!

CheddarGau · 2025-04-07T14:38:24-0400

So the hardest part of doing gears in the gear pattern. Make your own set up bearings, which will allow you to slide it on the pionon and side gears, make your adjustments check pattern, ad shims etc. If you have the space it is doable at home, especially the front, since its removed.

Same thing with the rear, but you only need to set the pinion depth, since there aren't side shims. You adjust them with a long rod hex.

Shops obviously want to make their money, but they also run the risk of you(any customer really) supplying wrong parts, then giving them a headache when it comes to paying for something that yielded no results. The other issue is, setting gears is more of an art than a skill and if they arent familiar with it, its super easy to lose time on it. No shop wants to lose time.

I just did the same thing, but work in a shop and do this stuff all the time.

Rene_05 · 2025-04-08T00:29:12-0400

u2slow said:
As long as you stay in 2wd, it won't matter what the ratios are.

I had the diff out for a whole summer, and had a 2wd-only KJ for the duration.

I might be thinking too hard about this, but just want to make sure I do it right. The gears in the front should be turning even if not in 4wd. Load is added when 4wd engaged (right?). How does it not create a problem if the rear is swapped to 4.10 before the front?

Some of the break in should include 4wd driving or does it not matter so much since they are Dana gears in the front?
Apologies if this has been answered in other threads, but I don’t remember seeing it.

CheddarGau · 2025-04-08T00:39:55-0400

Rene_05 said:
I might be thinking too hard about this, but just want to make sure I do it right. The gears in the front should be turning even if not in 4wd. Load is added when 4wd engaged (right?). How does it not create a problem if the rear is swapped to 4.10 before the front?

Some of the break in should include 4wd driving or does it not matter so much since they are Dana gears in the front?
Apologies if this has been answered in other threads, but I don’t remember seeing it.

Yes the gears are turning, but they are open diff and more importantly are disconnected from the transfer case. By leaving the t-case in 2wd, the front wheels and drive shaft are free spinning and are not being provided any torque. If you were to put it in 4x4 with different gear ratio something would twist (drive shaft) or whatever is the weakest component will blow up. I'm driving around with my rears as 4.11 and my front 3.73.....have been too lazy to install the other diff with 4.10 gears thats sitting on my bench. Need to soon.... need to hit some trails and camp.

CheddarGau · 2025-04-08T00:42:30-0400

Rene_05 said:
I might be thinking too hard about this, but just want to make sure I do it right. The gears in the front should be turning even if not in 4wd. Load is added when 4wd engaged (right?). How does it not create a problem if the rear is swapped to 4.10 before the front?

Some of the break in should include 4wd driving or does it not matter so much since they are Dana gears in the front?
Apologies if this has been answered in other threads, but I don’t remember seeing it.

In your case you are being overly cautious. Its better to be overly cautious in this case .

Rene_05 · 2025-04-08T00:58:20-0400

CheddarGau said:
Yes the gears are turning, but they are open diff and more importantly are disconnected from the transfer case. By leaving the t-case in 2wd, the front wheels and drive shaft are free spinning and are not being provided any torque. If you were to put it in 4x4 with different gear ratio something would twist (drive shaft) or whatever is the weakest component will blow up. I'm driving around with my rears as 4.11 and my front 3.73.....have been too lazy to install the other diff with 4.10 gears thats sitting on my bench. Need to soon.... need to hit some trails and camp.

Thanks, great explanation! After I posted I thought wait a minute, transfer case wouldn’t allow the front and back to ‘connect’ in 2wd.

4.10 Re-gearing - 2025

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