Beefing Your Axle Knuckles
Weld-on braces make it beefy
The stock Dana 44 axletubes found under the Jeep Wrangler JK are a light-duty version and feature a 2.50-inch OD tube diameter and a relatively thin wall thickness of 0.25 inches. Severe off-road activity can bend these front axletubes and create steering, alignment, and tire issues. Hammer the frontend for very long, especially after moving up to tires in the 35-inch–plus range, and your front axle can bend or break at the end forgings where the steering knuckles attach to the housing.
There is an inexpensive and easy-to-install remedy. Aftermarket kits to put sleeves in the axletubes or weld gussets on the end forgings are abundant. We decided to create a superstructure around the end forgings, and worked with Dunks Performance fabricator Casey Castle to walk you step by step through the installation of a set of TeraFlex’s upper (PN 4990800) and lower (PN 4990910) knuckle gussets, and to give some professional tips on this easy upgrade for the factory Jeep JK Dana 44 axlehousing.