DIY Regearing. Help!

[Mquerin]

Hi there! Very soon I plan on regearing my bronco from 3.73 to 4.46 with an eld. I might have jumped the gun because when I saw a rear sas axle for 600, I bought it. The right shaft is bent though but the housing and carrier look fine. I am going to buy the front fsd off a guy for 100 bucks with 4.46, and then regear the back to 4.46. Then new shaft, swap it all out, wire up, and procal. The only problem I’m having is finding a video or anything substantial online from people who have regeared.

has anyone out there regeared? How was it? Got any video, or advice?

My brother in law thinks I should just have a shop do it but idk I have the time since the axle is out so I figured whaat the hell why not give it a try.

So again, any advice or actual footage of this being done would help A LOT!

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[Oldhippie]

You will be throwing all the guts (diff & ring Pinon) away in the rear…if the housing is good (make sure it is straight) ya may want to have a good shop set it up the locker & ring pinion if ya have never done it before…just wire the locker to a switch…bolting the front and rear in is pretty straight forward…just a lot of taking apart/ putting back together…good luck

 

[Valhalla]

This is the same rear as jeeps, plenty of vids out there. Buy tools... You need the right tools. Case spreaders are great but not necessary. You will need a dial indicator. a press and a good torque wrench. I have set up a ton of rear ends, get a good set up kit. Get a bearing puller.

 

[Brian_B]

This is the same rear as jeeps, plenty of vids out there. Buy tools... You need the right tools. Case spreaders are great but not necessary. You will need a dial indicator. a press and a good torque wrench. I have set up a ton of rear ends, get a good set up kit. Get a bearing puller.

This. It takes a good deal of speciality tooling. The bearings are a pain to get off even with a clamshell puller. It’s not impossible to do in your driveway but I wouldn’t call it easy or for the faint of heart either. First time I went in blind, cut the old bearing off - then learned the hard way why @Valhalla says what he says. It’s not impossible but … tools make a huge difference. When all you have is a hammer you bend a lot of things that weren’t meant to be nails - or however that saying goes

You will need the gear pinion set and master rebuild kit with bearings and seals. You may also need the differential carrier - a lot of the non-ELD axles had the ring gears welded to the carrier and that just sucks, but is what it is. SAS carrier should not be welded - so should be fine there, but if you are looking at other 4.46 stuff some of that is.

I know you got the front and rear cheap but dunno if it’s gonna save you any money, even if you do the labor yourself and can borrow the tooling from a shop or auto parts store (sometimes they have this stuff for lending, but when I did it of course they didn’t have what I needed)

A lot of good threads around here about rebuilding and/or jus working in the diffs

I have a full non-ELD 4.46 rear end you could pick up for cheap cheap - just needs gear oil. But it has a welded ring gear so it wouldn’t be cheap to upgrade.

 

[BlueWaffle]

If you've never done it before, and it's your daily driver.. just pay to have it done.

 

[JT58Bronc]

I do a lot of my own work but not a differential tear down or re-gear. A very specialized job for sure that requires special tools, indicators, etc. I shopped a Jeep Gladiator back in 2020- getting a 4" lift, 35" tires and re-gear versus getting a Sas Bronco. Wow the Gladiator was going to cost for the re-gear.............

 

[Sidney073]

Hi there! Very soon I plan on regearing my bronco from 3.73 to 4.46 with an eld. I might have jumped the gun because when I saw a rear sas axle for 600, I bought it. The right shaft is bent though but the housing and carrier look fine. I am going to buy the front fsd off a guy for 100 bucks with 4.46, and then regear the back to 4.46. Then new shaft, swap it all out, wire up, and procal. The only problem I’m having is finding a video or anything substantial online from people who have regeared.

has anyone out there regeared? How was it? Got any video, or advice?

My brother in law thinks I should just have a shop do it but idk I have the time since the axle is out so I figured whaat the hell why not give it a try.

So again, any advice or actual footage of this being done would help A LOT!

What ratio is the SAS Rear Axle that you bought? I have a 2023 OB SAS that has the 4.70 ratio with 35” tires factory. If your SAS Rear is 4.70 I would keep that and rehear your front to match it, save some money.

 

[Valhalla]

That front regear can be a chore.

 

[1199Ducati]

$450 for gear set-up in my area of the country

 

[PWillette]

What ratio is the SAS Rear Axle that you bought? I have a 2023 OB SAS that has the 4.70 ratio with 35” tires factory. If your SAS Rear is 4.70 I would keep that and rehear your front to match it, save some money.

^^This^^...SAS axle should be 4.70s, no sense of tearing it down for taller gears. Find yourself a 4.70 FDU would be the way IMO.

 

[userdude]

When all you have is a hammer you bend a lot of things that weren’t meant to be nails - or however that saying goes

When all you have is a hammer, start swinging!!

When all you have is a hammer, you wished the numbskull swinging it had stopped hours ago.

When all you have is a hammer, you're definitely gonna drown.

When all you have is a hammer, dude go buy some tools.

 

[87-Z28]

When all you have is a hammer, start swinging!!

When all you have is a hammer, you wished the numbskull swinging it had stopped hours ago.

When all you have is a hammer, you're definitely gonna drown.

When all you have is a hammer, dude go buy some tools.

and yet the hammer is the best and most versatile tool ever made… can do almost anything, just never know how many whacks it will take.. for a caveman like me it really is a precision instrument.

 

[BroncoChallenger]

The jokesters showed up.

But I agree with your first few responses, if you're going to try to tackle it yourself, there's a lot of tools you'll want/need, you'll want a good clean area to do the work (preferably indoors), and get a lot of instructional videos under your belt.

OR.

Pay to have it done. If you've already supplied the gears and maybe the kits to do the rebuild, you're just paying for shop labor. A competent shop can do it relatively quick (probably drop off one day, pick up the next) and get you up and going.

 

[flip]

Differential Carrier - Vehicles With: Electronic Locking Differential (ELD)
Special Tool(s) / General Equipment

	204-069-01/1 Adapter for 204-069
	205-1058 Installer, Differential Side Bearing
	205-D017 (D80L-630-6) Step Plate, Universal
	205-D064 (D84L-1123-A) Puller, Bearing
Hydraulic Press
Punch
Copper Hammer

DISASSEMBLY

WARNING: The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates, it could cause injury, therefore do not maintain the rear differential tilted. When turning the rear differential, grasp the rotation handle firmly.

1. Remove the ELD solenoid.
   Refer to: Electronic Locking Differential (ELD) Solenoid (205-02A Rear Drive Axle/Differential, Removal and Installation).

1. Using the special tools and the general equipment, remove and discard the differential side bearing.
   Use Special Service Tool: 204-069-01/1 Adapter for 204-069. , 205-D017 (D80L-630-6) Step Plate, Universal. , 205-D064 (D84L-1123-A) Puller, Bearing.
   Use the General Equipment: Hydraulic Press

1. Remove and discard the ring gear bolts.

1. NOTICE: Care should be taken not to damage the differential ring gear bolt hole threads.
   Using the general equipments, remove the ring gear.
   Use the General Equipment: Punch
   Use the General Equipment: Copper Hammer

1. NOTICE: The differential flange and ring gear flange must be free of any old retaining compound material. Make sure both surfaces are clean and free of oil, dust and debris. Failure to clean the surfaces can result in ring gear runout concerns.
   NOTE: Use solvent and Scotch-Brite® pads to remove.
   Clean all traces of the old retaining compound material from the differential flange and ring gear flange.

ASSEMBLY

1. Install the ring gear onto the differential carrier. Align the ring gear using 3 new bolts. Using the general equipment, press the ring gear into place.
   Use the General Equipment: Hydraulic Press

1. NOTE: The component has a right-hand thread.
   NOTE: Install all the bolts finger tight before final tightening.
   NOTE: Tighten the ring gear bolts in a cross pattern.
   Install the ring gear bolts.
   Torque:
   Stage 1: 74 lb.ft (100 Nm)
   Stage 2: 40°
   

1. Using the special tool, install the new differential side bearing.
   Use Special Service Tool: 205-1058 Installer, Differential Side Bearing.

1. Install the ELD solenoid.
   Refer to: Electronic Locking Differential (ELD) Solenoid (205-02A Rear Drive Axle/Differential, Removal and Installation).

1. Check the differential ring gear backlash.
   Refer to: Ring Gear Backlash Adjustment (205-02A Rear Drive Axle/Differential, General Procedures).

 

[PWillette]

Easy peasy

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