Yukon Gear and Install Kit Package For Jeep XJ Cherokee With Dana 30 Front and Chrysler 8.25in Rear in a 4.88 Ratio

Complete Front and Rear Re-Gear Kit for 1991-2001 Jeep Cherokee XJ, Dana 30 and Chrysler 8.25in, Part YGK004

The Yukon Gear YGK004 gear and install kit package covers everything needed to re-gear a 1991-2001 Jeep Cherokee XJ equipped with the reverse-rotation Dana Spicer 30 front and the Chrysler 8.25 inch rear differential. This kit delivers matched 4.88 ring and pinion sets for both axles along with Yukon Master Overhaul Kits containing all bearings, races, seals, and shims. The YGK004 simplifies the sourcing process by combining four part numbers into a single order, making it the most straightforward way to complete a Cherokee re-gear for larger tires or improved off-road performance.

Features and Benefits

• Engineered for 1991-2001 Jeep Cherokee XJ with reverse-rotation Dana 30 front and Chrysler 8.25 inch rear differentials
• 4.88 ring and pinion ratio optimized for 33-35 inch tires with restored power and towing capability
• Front and rear ring and pinion sets forged from 8620 steel with vacuum heat treatment and CNC precision machining
• Yukon Master Overhaul Kits for both axles included, with all bearings, races, seals, and shim packs
• Computer-controlled lapping process ensures quiet, consistent gear mesh and long service life
• Yukon Y.E.S. Plan provides lifetime warranty coverage for as long as you own the vehicle
• Note: If currently running a 3.54 ratio, a new front carrier is required and sold separately
• Made in USA

Vehicle Fitment

Specifications

What's Included

• Front ring and pinion gear set (Dana 30 reverse rotation, 4.88 ratio)
• Rear ring and pinion gear set (Chrysler 8.25 in., 4.88 ratio)
• Front Yukon Master Overhaul Kit (bearings, races, seals, shims)
• Rear Yukon Master Overhaul Kit (bearings, races, seals, shims)

Frequently Asked Questions

What vehicles does the YGK004 fit?
The YGK004 fits 1991-2001 Jeep Cherokee XJ models with the reverse-rotation Dana Spicer 30 front axle and Chrysler 8.25 inch rear axle. It also fits Jeep YJ Wrangler equipped with the same axle combination.

What does reverse rotation mean for the Dana 30 front in the XJ?
The Jeep XJ uses a high-pinion (reverse-rotation) Dana 30, where the pinion approaches the ring gear from above rather than below. This design requires a ring and pinion set specifically cut for reverse rotation. The YGK004 includes the correct reverse-rotation gears.

Do I need a new carrier if switching from 3.54 gears?
Yes. If your Cherokee is currently equipped with a 3.54 gear ratio, the front carrier must be replaced due to different carrier break (spread) requirements. This carrier is sold separately.

Will the YGK004 affect my factory warranty under the Magnuson-Moss Warranty Act?
Under the Magnuson-Moss Warranty Act, a manufacturer cannot void your warranty based solely on the installation of an aftermarket part. The YGK004 is a precision-fit component and should not affect unrelated warranty coverage. Consult your dealer for specifics on any remaining coverage.

What warranty does Yukon provide on the YGK004?
Yukon covers the YGK004 under their Y.E.S. Plan, a lifetime comprehensive warranty against defects for as long as you own the vehicle.

Does the YGK004 include all bearings and hardware?
Yes. Both front and rear Yukon Master Overhaul Kits are included, covering all bearings, races, seals, and shim packs required for complete installation on both axles.

What tire size is the 4.88 ratio best suited for?
A 4.88 ratio is well matched to 33-35 inch tires on the Cherokee XJ, restoring factory highway RPM and low-end torque for improved off-road and towing performance.

Is professional installation required for the YGK004?
Professional installation is strongly recommended. Setting ring and pinion gear backlash and contact pattern requires a dial indicator and bearing driver set at minimum. Incorrect setup can cause premature gear wear or failure.

Installation Instructions

1. Raise the vehicle on a lift and secure on jack stands. Drain differential fluid from both front and rear housings.
2. Disconnect the front and rear driveshafts from the axles.
3. Remove the rear Chrysler 8.25 inch differential cover and disassemble the carrier and pinion.
4. Press bearings from the old carrier and pinion using a bearing press.
5. Install new pinion bearings from the YGK004 Master Overhaul Kit and set pinion depth with a dial indicator.
6. Install the new Chrysler 8.25 inch ring and pinion from the YGK004 and torque ring gear bolts to spec.
7. Set carrier backlash to 0.005-0.010 in. using carrier bearing shims.
8. Verify gear contact pattern with marking compound and adjust shims as necessary.
9. Repeat the disassembly, bearing replacement, and setup procedure on the front Dana 30 reverse-rotation axle.
10. Reinstall both differential covers with new gaskets and torque to specification.
11. Refill both differentials with the appropriate gear oil and reinstall driveshafts.
12. Road-test the vehicle and re-check differential covers for leaks after the first drive.

Prop 65 Warning: This product can expose you to chemicals including arsenic, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, go to www.P65Warnings.ca.gov.