dodge35000

I just finished installing 4.56 gears in my 2004 Dodge 2500 -- here are some of the PICS.


Factory backlash @ .008

Factory coast side

Factory drive side

4.56 pinion & 3.73 pinion

1st pattern backlash set at .009

1st pattern, drive side, w/.055 pinion shim -- too shallow

1st pattern, coast side, w/.055 pinion shim -- too shallow

2nd pattern backlash set at .008

2nd pattern, drive side, w/.070 pinion shim -- perfect

2nd pattern, coast side, w/.070 pinion shim -- slightly deeper


I finished the AAM 11.5 rear axle; however, I still have to do the AAM 9.25 front axle with Detroit Trutrac. I will take a few PICS of that install also.

I have a lot of actual install pictures, but this should keep most people busy for a while. This is also posted on Dodge Cummins Diesel Forum.

dodge35000

PICS continued


19 in/lbs Pinion torque to rotate(PTTR)

37 in/lbs Total torque to rotate(TTTR)

Final drive pattern, .070 pinion shim, .008 backlash

Final coast pattern, .070 pinion shim, .008 backlash

I finished the AAM 11.5 rear axle; however, I still have to do the AAM 9.25 front axle with Detroit Trutrac. I will take a few PICS of that install also.

I have a lot of actual install pictures, but this should keep most people busy for a while. This is also posted on Dodge Cummins Diesel Forum.

DENVERDODGE04

man i wish i knew how to do gears.. I want 4.10's so bad.......

WhozNxtLS1

I have no clue what was going on ......I want a posi, and 4.10's ahahaha

timcasbolt

Nice pattern!

dodge35000

I just added a new poll to see what people think about trying the gear install themselves. Well let me know what you think.

stock03

You make it look too easy. I don't think I'd try it by myself on my daily driver. I have 4.10's, and 3.73's would be nice.

levigarrett76

The hardest part is having the patience to get everything set right!

I think the most PITA axles to set up are dana's

instead of the adjustable sleeves on the carrier bearings you have to press the bearings on and off to change the shims or use some setup bearings.


Nice writeup.....i really like that snap on inch lbs. gauge

zuki_dan

I set up gears on helicopters everyday, and if you have the right tools and some mechanical know how anybody could setup gears with some instruction.
I installed the limited slip in my truck and the carrier brg adjuster sleeves make carrier preload and backlash easy. I knida want to put 4.10's in my truck but don't want to spend the money on the gears.

dodge35000

The Poll is just about up. If you are reading this, take a minute to vote on it.

Brian08Q35004x4

Nice write up. I think a fully documented and photo write up is the kind of things that would make this forum standout.A forum on how to do upgrades would really make a difference. and is really a rewarding experience to all. Once again great stuff!

joesixpack

Nice work.

little red man

I know this is an old thread, but if I could have I would have voted "I want to learn how to do it myself. A write-up would give me the confidence to try. " based on an issue I had with my diff. Long story short, I just finished replacing all bearings in my rear end. I kept the gears, because as near as I can tell, they are fine (but maybe I could be wrong).

Regardless, I am in what I think are the final stages of the build, but I am not happy with the pattern. The attached pattern (sorry, the pics are not great) does not resemble the pattern I got (sorry no pics of that) when I was using dummy bearing to set pinion depth, and so I am thinking that the new bearings added a bit of depth to the pinion (again, could be wrong).

Anyway, keep in mind these are used gears, and so my focus has been on the coast side to an extent. I am using the diagram as a guideline. Any thoughts on this pattern?






Descriptor for the Drive side, is that the majority of the pattern is on the toe, but that the rest of the pattern is highly variable.




11 thou backlash. These were the non-painted teeth. Coast.




11 thou backlash. Painted teeth. Drive. Seems deep to me, but I sure ain't no expert!

little red man

Coast at 6 thou. Non painted teeth.




Again, coast at 6 thou, but painted teeth.




Drive at 6 thou, painted teeth




6 thou drive, cleaned teeth. Pattern to me looks very similar to painted. These are not too worn to re-use, are they?