I'm in the process of strengthening my Dana 44 front axle with sleeves and gussets. I was test fitting the Teraflex C-gussets and noticed that there was some significant gap at the top. This got be thinking that I may possibly have already bent my C's slightly. Is there a may to measure this with the axle off of the Jeep?

 

Take it to an alignment shop.....or grab a large level and see at what angle the hub sits. Obviously make sure the bj's are good or that'll throw off your numbers.

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I already removed the hubs unfortunately. I was thinking of taking a straight edge and putting through the ball joint holes and measure the angles of both?

 

A signifiant gap at the TOP would not be indicative of your Cs being bent in the fashion they normally would be. Just the reverse. There really is no ACCURATE "garage" way to judge if they are bent in your current state of disassembly but it would sound as if they are not. If you aren't already, don't think twice about going ahead and replacing your balljoints now if you haven't done so.

 

I read somewhere that the c should measure 9 1/16" to 9 1/8" machined surface to machined surface. Assuming I remembered the dimensions correctly. I can take pics when I get home.

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I would imagine that to be a good gauge unless the bottom bent with the top. After all, they're both bolted to the knuckle via balljoints.