Re-gearing my 1991 yj -
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post #1 of 5 Old 02-12-2011, 11:48 PM Thread Starter
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2006 TJ Wrangler 
Join Date: Mar 2009
Location: georgia
Posts: 6
Re-gearing my 1991 yj

I have a 4 or a 4.5 inch suspension lift with a 3 inch body lift. I am currently running 35x12.5 pro comp all terrains on the stock axles/gears. I havent really researched it much, i figured someone on hear could give me a hand. What kind of gear ratio would be best with the set up i have (4cyl amc 150, stock transmission, etc.). Also, my four wheel drive will engage into 4 low, however the front axle is not catching to rotate the tires. I really have no knowledge of the mechanical components inside the differential or the transfer case but im gotta learn somehow. If anybody has any advice for me that would be great!

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post #2 of 5 Old 02-13-2011, 08:20 AM
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1988 YJ Wrangler 
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Location: Baltimore
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As far as your re-gearing I'd go with 4.88's in the Dana 30 & 35. That's the lowest gear set those axles can accommodate. Factory has 4.10's which is good for stock and possibly up to a 31 or 32" tire, but it gets Very difficult to maintain speed on the highway. You'll probablly want to look into a Dana 44 rear or a Ford 8.8 out of an explorer. They'll hold up better than the Dana 35 with the increased weight and stress of the 35" tires.

For the transfer case/ front drive shaft issue, the shift fork collar on the axle disconnect might not be fully engaging? There's a cover plate on the back right side of the front axle, this is the disconnect. If they loose vacuum or proper connection they will not function properly. Fixes are (least expensive to most$$): junkyard late model Cherokee or 97+ Wrangler passenger side axle shaft, posi-lock or warn chromoly cad delete shafts. Hope this helps.
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post #3 of 5 Old 02-13-2011, 09:11 AM
XJ on 37's
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1998 XJ Cherokee 
Join Date: Jul 2006
Location: missouri via blackpool,lancs.
Posts: 10,625
Go to the YJ tech section and read the FAQ.
All your questions are covered there, as well as the next 25 you were thinking of asking...


1998 XJ on 37's.JK Rubi axles with chromo shafts and ctm's, 4:1 transfer case, etc etc etc.
2003 Range Rover HSE, 4.4 Quad Cam.
1998 Range Rover with a 6.0 LSx
1994 YJ, 4.3/700R4/OME SOA, etc
Western Star 4900EX 4 axle.
4.3/700r4/new frame buildup (YJ)....

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post #4 of 5 Old 02-13-2011, 10:22 AM Thread Starter
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2006 TJ Wrangler 
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Location: georgia
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Alright, i appreciate it, hopfully this will help, im currently trying to graduate from college so hopefully i'll have some time to look into your advice. i really have no income so funds come and go as they please, haha
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post #5 of 5 Old 02-13-2011, 10:46 AM
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1988 YJ Wrangler 
Join Date: Oct 2010
Location: Baltimore
Posts: 243
Well the Nutter is pretty much free! Good luck with your build!
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