How to Install a Yukon Gear Dana 44 Locker: Step-by-step Power Enhancement Guide

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Installing a Yukon Gear Dana 44 Locker can significantly enhance the performance of your vehicle, especially in off-road conditions. This step-by-step guide will walk you through the installation process, ensuring you achieve optimal results.

Tools and Materials Needed

  • Yukon Gear Dana 44 Locker kit
  • Socket set
  • Torque wrench
  • Ratchet
  • Jack and jack stands
  • Wheel chocks
  • Grease
  • Safety glasses
  • Gloves

Preparation Steps

Before starting the installation, ensure you have a clean workspace and all necessary tools at hand. Follow these preparation steps:

  • Park your vehicle on a flat surface.
  • Engage the parking brake and place wheel chocks behind the rear wheels.
  • Lift the front of the vehicle using a jack and secure it with jack stands.

Removing the Differential Cover

Start by removing the differential cover to access the internals. Here’s how to do it:

  • Use a socket to remove the bolts securing the differential cover.
  • Carefully pry the cover off with a flathead screwdriver.
  • Drain the old gear oil into a suitable container.

Removing the Old Carrier

Next, you need to remove the existing carrier to make room for the new locker:

  • Remove the axle shafts by taking out the C-clip or retaining ring.
  • Unbolt the carrier from the housing using a socket.
  • Carefully pull out the carrier from the differential housing.

Installing the Yukon Gear Dana 44 Locker

Now it’s time to install your new Yukon Gear Dana 44 Locker:

  • Clean the differential housing thoroughly.
  • Install the new locker into the differential housing, ensuring it fits snugly.
  • Align the locker with the pinion gear and ensure it is seated correctly.

Reinstalling the Axle Shafts

After the locker is installed, you need to reinstall the axle shafts:

  • Insert the axle shafts back into the differential.
  • Secure the shafts with the C-clip or retaining ring.
  • Ensure the shafts rotate freely and there are no obstructions.

Reattaching the Differential Cover

Once the axle shafts are in place, reattach the differential cover:

  • Apply a new gasket or sealant to the differential cover.
  • Position the cover back onto the differential housing.
  • Tighten the cover bolts to the manufacturer’s specifications using a torque wrench.

Refilling the Differential with Gear Oil

After securing the differential cover, refill the differential with gear oil:

  • Remove the fill plug from the differential.
  • Using a funnel, pour the recommended gear oil into the differential until it reaches the fill hole.
  • Replace the fill plug and ensure it is tight.

Final Checks and Testing

Before taking your vehicle for a drive, perform these final checks:

  • Double-check all bolts and connections for tightness.
  • Inspect for any leaks around the differential cover.
  • Lower the vehicle from the jack stands and remove wheel chocks.

Conclusion

Installing a Yukon Gear Dana 44 Locker can enhance your vehicle’s off-road capabilities significantly. By following this step-by-step guide, you can ensure a successful installation and enjoy the benefits of improved traction and power.