Beef­ing Your Axle Knuck­les

Weld-on braces make it beefy

Jp Magazine - - TABLE OF CONTENTS - By Bruce W. Smith jped­i­tor@jp­magazine.com Pho­tog­ra­phy: Bruce W. Smith

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.

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