Since I bought my JK and reading several posts regarding the C gussets, I'm wondering if that area is a weak spot that the d30 didn't have. I've run my ZJ fairly hard, but carefull not to ram or try to bull my over or through anything and have never had an issue with the Cs on 33" tires. Yet, that seems to be the first thing many want to add to their front d44. Is it the 35" tires that are that much more stress on the axle? No doubt, they will make the axle stronger and I will be adding them, but was wondering why the 44 has a problem and, at least for me, the d30 in the ZJ is fine.

 

The only difference between the D30 front and D44 front in the JK is the housing (and of course carrier, ring gear, etc).

The point is, the tubes, bracketry and end forgings are the same: prone to bending.

If you wheel you need the gussets, no two ways about it.

 

if you run 35's, the axle C's will bend unless they are gusseted. the C's are the same on the 30 and the 44.

 

looks like most people go with the EVO ones that are around $90?? Is it just the front axle that need the gussets or do you need them for the rear as well?

I've seen different looking trusses that fit over the differentials...are those better/worse??

I'm so new to all this mod stuff and I had no clue that a lift and bigger tires would mean so many other mods would be required! I'm so broke!!!

Edit** Looks like its both as the Evo kit seems to have 4 gussets**

 

There are several different C gusset designs now, teraflex has some, and others. They make exterior trusses for them as well as the sleeves to keep the entire tube from bending. I have not done either to mine, just the gussets. The nature of the sleeves deters me from them, I'm scared my tube is slightly bent and will drill a dozen holes in my axle to find out it's bent! I'm thinking exterior truss when I do beef it up completely.

 

you only need them up front and the EVO ones are what i run. nothing is needed for the rear and in spite of what some may try to suggest, they are the only thing that is needed. the trusses and sleeves are not needed and will do nothing to support your axle C's.

 

I was thinking of the inner sleeves and gussets, but question if I need the sleeves. I'm running 34" tires and have never (Shouldn't say that) had a problem with the d30 in my ZJ which is about the same weight, so maybe the gussets will be adiquate. What do you think, WOL?

 

i don't want to speak for WOL but based on his response to me, it seems only the gussets are needed to fix the issue our axles have (D-30 or D-44). I was about to buy the EVO ones but someone mentioned Teraflex also sells some and they are about half the price ($42). Hmm...

 

the sleeves are nice to have but, contrary to what some will suggest, are far from needed. the axle c's do bend - i have personally seen it happen and see it happen on other JK's all the time. in over 60,000 miles, i had not seen my white JK's dana 44 axle tube bend and most of those miles were done while running 37" toyo's.

 

For what it's worth I have seen the aftermath of an axle tube break. The vehicle was a four door running 35's. The tube broke just to the right of the lower control arm mount. The owner is a member of our local jeep club and this forum. The tube broke after bumping a rock with his rim. The rim was scraped but not bent. The tube fractured completely. Probably brittle/poor quality tube. I would definitly add the tubes if running the added weight of a 4 door.

If the link works, check out his original post on our jeep club's site:

northernjeep.proboards.com/index.cgi?board=general&action=display&thread=1387