Smoked rear e-Locker in a 2021 non XR 392 w/3.73 gears. New axle assembly ordered. Mopar 4.56 gears wanted!!!

justinB

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For more visibility, my two comments from another thread inserted here. Please see my latest Update post at the bottom.
Thanks, J.

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Gearing Advice Please!!!

My non XR 392 w/3.73 gears is at the dealership now. Swung by last night and they said to leave it and they would take a look at it today. My rear electronic locker messed up (I Think). It was making a clucking noise only when turning at slow speeds and when switching on/engaging 4 low it does not mechanically engage. The idiot light came on as well.

Anyways, the service manager said that sometimes when the e-locker fails they have to replace more than just the locker. They may have to replace the gears... and sometimes the entire axle, dependent upon how much damage 'spread around' inside the housing. Makes sense if the locker's components are getting smashed in between the ring and pinion and other moving parts. I mentioned if they have to replace the rear gearing, which is covered under warranty, what would it cost/take to swap the rear gearing out to 4.56 (which they may be able to 'slip-in-there' to be warranty covered), but then to also replace the front gears to 4.56 as well?

My assumption is the rear gear replacement (if they say it's required) should be at a near zero cost as it's warranty work and I can't imagine that much of a difference in cost between 3.73s and 4.56. Of course I'd have to pay for the front.

With that I got to thinking. I run 35" tires and I do haul a ~3500lb camper trailer from time to time. I'm not sure I'd ever go larger than 35" tires, but if I ever went to 37s let's hear your advice on the below...

Knowing that I do haul, with 35" tires would y'all go to 4.56 gears or perhaps 4.88? What if I went to 37" down the road and I wanted to be haul/gear ready? Would the 4.56s be good enough or should I go to 4.88s?
Perhaps for now let me stay in my current world. With 35" tires would you select 4.56 or 4.88 gears?

Also, anyone know what it might roughly cost to have the front gears done?
I know the dealership will probably cost more than a private shop, but I want to maintain the warranty.

Thank You All for any advice.

~justin

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Update:

Here's where I'm at...
I have a 2021 non XR 392 with 35" tires and I tow a 21 foot ~3,500lbs camper trailer monthly. I mention that because the camper has wind drag, it's not the weight so much. The 4.56 gearing will help alleviate powertrain strain.
I'm attempting to be very detailed here because I'm hoping someone may have a suggestion on Mopar 4.56 gearing...

The rear locker was fried. My intent was to have the dealership replace only the locker and I'd be done with it, it'd be fixed and it would have the original 3.73 gears. My initial request, before they opened the differential, was IF they had to replace the differential or gears because of the defective e-locker's collateral damage then to put in 4.56s (I'd pay the difference in the warranty work covering the rear end, if there was any, and of course I'd come out of pocket to have the gearing installed up front). My thought, If they did the work and installed Mopar parts I'd retain warranty coverage and it'd only cost me half as much only paying for the front gears.

Visiting the dealership the next day, the dealership was not able to find 4.56 gears (the ring & pinion set by itself OR a differential assembly w/4.56) in their system for a 2021. They found 4.10s for a 2022 but their system (the parts guy) said since these gears were referenced to a 2022 axle model they may not fit in a 2021 axle housing. As they were uncertain if 2022 4.10s would fit a 2021, they were not willing to chance other gears fitting a 2021 axle as well.

(((Personal thought. I'm not sure I believe there's a difference in the 2021 vs 2022 axles, perhaps their system did not find the gears because Mopar is out of stock on 4.56 gears, I think an unlikely reason though. Or perhaps user error not finding them in the system [all due respect-great guys & gals working there]. Anyways, who knows... Obviously, I don't want the 4.10s, the whole purpose was to see if other gears would actually fit the 2021. And in all fairness the only 392 the service members have worked is mine, there's no hands-on shop experience/knowledge regarding the 392 of any year.)))

Due to a shortage on individual parts e.g. the actual e-locker, and due to a shortage on differentials, they are replacing the entire axle assembly. Gasp! What? Just craziness. And that's with the 3.73 gears, obviously. I could buy both front & rear 4.10 axle assemblies for ~ $9k, but that's not going to happen AND no one could tell me if 2022 axles would even fit. Regardless, I'm not paying ~9k nor do I want 4.10s.

The dealership said IF I was able to do my research and found/bought Mopar 4.56 gears separately they would charge me only for the front & rear install to include updating the PCM and I'd retain warranty.

Like the parts guy, I'm unable to find 4.56 Mopar gears for a 392 which has the WIDE D44 axles. Does anyone know the Mopar part numbers for front and rear 4.56 gearing that'll fit a 2021 non XR 392? My concern, I buy 4.56 gears for a Rubicon but those gears end up not fitting the Rubicon 392's Wide D44 axles.

The link below displays 4.56 gearing for a 392; however, since it's not Mopar I chance losing my powertrain warranty coverage if I have them installed. I'll also include some pics of the defective e-locker and the quote which displays the part number for both the front & rear wide axle housings, the 3.73 gearing for a 2021 392 which is what's currently on my Jeep. This so there's a reference point if anyone knows if/what Mopar 4.56 gears will fit it. That's now my intent, just buy the front & rear Mopar gearing and have the dealership perform the install.
In a worst-case scenario I buy non-Mopar gearing and potentially forfeit my remaining warranty. If it saves my transmission 5 years down the road, then perhaps it's worth it.


Thanks All for any positive input.

~justin

Dana 4.56 Rubicon Dana 44 210MM/220MM Gear Package; Wrangler JL with Master Install (rubitrux.com)
 

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The 4.56 gear was only available with the XR package. They will work in your diff. If you can find them. Parts guy should know this. Mechanic definitely should. I would hope anyway.
 
The 4.56 gear was only available with the XR package. They will work in your diff. If you can find them. Parts guy should know this. Mechanic definitely should. I would hope anyway.
That's the issue. The parts guy was not able to find MOPAR 4.56 gears. No mechanics at the dealership have worked on a 392 other than mine. Perhaps if a had a VIN for an XR that would help them narrow in on gears... IF you are certain XR 4.56 gears will fit within my non XR axle.
 
Sorry I missed this. Let me know if you still need a vin.
 
Axles are the same, gear set is different.
That's the issue. The parts guy was not able to find MOPAR 4.56 gears. No mechanics at the dealership have worked on a 392 other than mine. Perhaps if a had a VIN for an XR that would help them narrow in on gears... IF you are certain XR 4.56 gears will fit within my non XR axle.
 
Dana 44 is dana 44...almost any gear set will work for a Dana 44 rearend...I would buy Yukon with lifetime if it were me.
 
Dana 44 is dana 44...almost any gear set will work for a Dana 44 rearend...I would buy Yukon with lifetime if it were me.
Unfortunately, that is not true, from what I've learned.

There is a Dana 44 and a Dana 44 Wide. My 392 has the Wide. Not all 392s have the "Wide" axle (and the "Wide" designation code/term is not referring to axle length); therefore, not all Mopar gears for a Wide axle will fit a 'regular' axle & vice versa. The housing is different. This per the dealership's parts manager. He was online with me for an hour deciphering all this. And to boot, there are Not only two iterations of the 392 axle, there are several.
[Absolutely mind boggling why this is the case.]
 
Axles are the same, gear set is different.
Regarding the axle, see my post above this.

What I was attempting to do, as the dealership had to replace the entire rear axle because I smoked my rear locker, is find out what axle assembly part number would fit my specific 392 that has 4.56 gears pre-loaded and have them install that axle. I would then only have to buy the front 4.56 gears. This became a more difficult task than I would think.

Again, per my previous post, there are several iterations of the 392 axle.
Obviously, the axle assembly part number would be different if it has different gears, even if the axle by itself has the exact same axle, or rather, the same part number if it were sold bare or separately.

MY 2021 non XR 392 that has the Wide designator regarding its axles.

Here is the part numbers that are on my specific 392 Wide axles with the 3.73 gears.

Front: 68544568AA = Axle Assembly with 3.73 gears.
Rear: 68544447AA = Axle Assembly with 3.73 gears.

Here are the Mopar part numbers for the 4.56 gears (Ring & Pinion kit) that will fit within the axle assembly housing on my specific axles. Again, per the parts guy, 392 gears within D44 axles are not all interchangeable.

Front: 68548480AA = 4.56 Ring & Pinion kit
Rear: 68549532AA = 4.56 Ring & Pinion kit

If anyone has the same 3.73 W axle assemblies I have and want to swap to 4.56 gears I really hope this helps, a nightmare for me getting all this deciphered.
 
I would not do it, have owned both and I have xr and 37's and my brother has non xr and 35's and we agree the 35 is perfect with the 3.73 all around. Yes the XR has great power everywhere but our fuel economy difference is 2mpg plus

what I would do is 4.10's

if you do the math the way it is supposed to be done, to keep the Jeeps consistent the XR with a 315 should have a 4.11-4.12 but the XR was done to be the Bronco Beater as the Jeep was losing in some category, I cant recal, Jeep said watch this hold me beer- here you go Ford I will beat you and raise your some and thats how the xr got overgeared in my opinion.

My old 392 was sold with 35's, the buyer went to the new Nitto 38's with 22's and a small puck lift and she is complaining its now a sled.
 
I changed the gear oil recently. I couldn’t tell if they are 4.56 gear ratio. I originally thought they’ll have the 4.56 stamped on the side of the ring gear.

Front axle: Dana M210
Rear axle: Dana M220

My understanding is XR and non-XR 392 use the same axles except the gear ratio kit.
 

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Normally it is 2 sets of 2 numbers that you divide to get the ratio. And stamped on side of ring gear.

OP: With regards to damage RP set, was it possibly caused by the locker solenoid being filled with gear oil?
 
Normally it is 2 sets of 2 numbers that you divide to get the ratio. And stamped on side of ring gear.

OP: With regards to damage RP set, was it possibly caused by the locker solenoid being filled with gear oil?
I'm not really sure. I do know that when the dif was opened up it had metal flakes all throughout. Also, with the Jeep lifted, when I pivoted the right rear tire/wheel I could hear clunking coming from inside the dif. It sounded like a dif bearing had failed allowing the axle to kinda shift around inside the dif. Since Jeep did the repair, I wasn't really able to get in there and see what actually failed. I'm not sure if Jeep just went with "The Locker is Not Engaging; therefore, the locker is at fault", when perhaps a bearing failed which allowed for destruction the locker. Since the whole axle was replaced, no real dissecting was done.
 
So at the end, did it work out for you?
I have 2022 non XR and I'm interested in regearing to 4.56 while maintaining warranty.
 

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