Rear End Gear Swap

Time to change out these salt flat gears!.

1-12-2011

The kit came with an optional 9 rear end which was very nice but, it had 2.75 gears and it was open. I wanted to upgrade to a posi and lower the gears to a more usable ratio. As it was, 5th gear was useless and 1st was way too tall for traffic.

 

First step was to find out what axles I had, 28 or 31 spline. I pulled the passenger axle out and discovered that it was 28. This allowed me to order the correct unit, along with the yoke measurements.

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First thing to do was to remove the wheel and breakdown the brakes. After four bolts holding the bearing retainer, a few tugs on the axle and out it came. Being fairly new, it came out very easy. In the past on other projects, I have had to use a slide hammer and a lot of band-aids!

I ordered the pumpkin from TJs 610-485-4858 after speaking with him a couple of times on the phone. I highly recommend talking with him if you are in need of a rear end change, he knows his stuff and is more than willing to work with you. I ordered it with 3.50 gears, Trac-Loc and a new nodular carrier. Being Christmas weekend, it took a little longer on shipping, but I did receive it in about a week.

 

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I began by removing both brakes, bolts holding the bearing retainers and then removing both axles. I then removed the drive shaft and wired it up out of the way.

 

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I removed all the bolts holding the main unit to the housing and then took a 2x4 and placed it on the side of the pumpkin. I used a 5lb shop hammer to strike the 2x4 and break the seal loose. Make sure you have plenty of cardboard or other covering down because this makes a big mess.

 

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After completely draining the diff, I positioned my floor jack under the pumpkin section and worked it out of the housing. Be careful because this thing weighs 75lbs and is not flat or balanced.

 

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I then cleaned up the surfaces and installed a gasket that came with the new unit. I used the same floor jack to position the new unit in the housing and replace the nuts. Then the axles went in being very careful not to damage the seals. I finished by reinstalling all of the brakes like they were removed and then filled the rear with friction additive that came with the unit and new 80/90w oil.

All took about 3 hours and was not too difficult.

Being 35 degrees outside, I then took a longer than necessary test drive and love the new gearing. I now can use 5th and the gearing is much more usable.

Anybody need a slightly used 9 open 2.75 pumpkin?

 

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