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"Re-gearing" is completely unrelated to the deletion of the air actuated free wheel mechanism - the only commonality is that both can be done at the same time.You can "re-gear" and leave the air actuated mechanism in place, or, you can weld the dog clutch thereby permanently engaging them without touching the gearing."Re-gearing" is only required if you are running larger tires, and even then, only once you exceed a certain size - I'm running tires that are a little over 6% larger than OEM and see no need to re-gear, however, the dog clutches in my front diff do slip from time to time (it's audible when it happens - this was happening on OEM sized tires, so it's not related to the increase in tire size), so at some point I will weld the clutches engaged - manual free wheel hubs have already been fitted.
easier way is regear
So after a bit of thought I realized that the MIG welder may not have gotten penetration on the case hardened steel. Out came the diff again and lo and behold sure enough every one of the eight tack weld had popped. So we improvised redneck Style and added some chunks of Steel to lock open the actual actuator ring. Now to test it.