I bought a set of rubi axles with 3.73 gears, complete. Then had them trussed and armored by a professional. Now for the regearing- I can't get the 5.38 gears to mesh correctly. They are Dana gears, with dana master sets.

 

What do you mean mesh correctly? What step are you on? I assume you have the pinion in and are attempting to install in the carrier/ring gear? Take out the spacers, measure the width of the one on the side opposite of the locker actuator, and put a significantly thinner one in that spot to at least test fit it up. Then check backlash and adjust from there. Once you have the backlash adjusted, then go ahead and cram spacers in the other side to make up for the difference, recheck backlash and check engagement profile. Adjust as needed.

 

I think my spacers are too thick.

 

The stock ones that were installed will be (or at least it will be for one side). You should have received new shims with the gears. If you did not, you need shim kit.

 

I have the master sets.

 

Dont mean to be a dick, but gears arent something for the first timer. Doing it wrong could lead to serious problems down the road.

What is your backlash? What is your pinion preload? Do you have a dial indicator? Do you have a beam style inch pound torque wrench? I can point you are inexpensive options if you dont.

 

Have a reputable shop do it. Unless you've got plenty of experience doing gears, your jeep and the extra $ spent on it is worth it. I'm glad I did as there are too many very technical bits to worry about

 

Aren't all rubicons 4.10?

 

That used to be true.

 

I think this stopped with the introduction of the Pentastar in 2012. Then it changed to 3.73 for default on the auto and 4.10 on the manual with an optional 4.10 on either.

When I got my 2016 the 4.10 were a couple hundred dollar option.

There are many late model Rubicons on 3.73s.