There’s no easy way to say this, and it's a little embarrassing, but it’s my hope that others might learn from my mistake! Obviously, this is a topic you see brought up over and over again, and the subject of endless debate. I think amongst the more experienced wheelers, there’s much less of a debate. But anyway, I just want to chime in and add my story, even if only to serve as a warning to others!

After a very active couple months, wheeling every weekend on big rocks and beating the crap out of my rig, I noticed that I likely had bent a rear passenger axle shaft. Took it into the dealer and discovered that no, in fact both of my rear axle flanges were bent. Good thing it’s under warranty!
I had also been considering hopping up in wheel size (from 33” MTRs) and adding some muscle to the front axle, regearing, etc. But, since I’m impatient, I figured I would be OK if I bought new wheels and tires (37s) first, and took it easy for a little while and built everything up. I think you see where this is going...

Well, on my brand new 37 MTRs and my brand new factory axle shafts, I bent both the new rear axle shafts this weekend! I didn’t even have any hard impacts, just some little crawls and some tests to check clearances/bumps at full stuff, etc. It was an easy-peasy weekend on trails that I know very well. Still, I managed to bend both rear shafts! I haven’t been able to check the fronts yet… but I’m not convinced I haven’t hurt them too. Only took me a week to ruin brand new shafts

So, if it’s worth anything coming from a relative noob: you should reconsider running 37s on stock D44 shafts if you do any kind of regular crawling.

 

Time to go aftermarket. A decent set of alloy shafts will handle the tires/weight better, and both TenFactory and G2 will warranty bent rear flanges - if you bend them.

 

Always been curious how much stronger chromoly rear axle shaft flanges are than stock. Percentage wise anyway like 20% stronger? 100% stronger?

 

Depends on the metal/alloys used. 1541h, 4130, 4140, 4340? And probably on the manufacturing location/process, heat treatment, whatever else. 1541h isn't much stronger than stock. 4130/4140 are reported to be 30% +/- stronger than stock. 4340 I think I read is closer to 40%

Also read that the flanges are not hardened on stock and 1541h shafts, but are hardened on the others. This makes sense to me, since we always hear about bent stock flanges, and don't get reports of very many bent alloy flanges. (and the guys that do bend alloy flanges, well, most of them are used to swapping shafts on the trail...)

 

Dont forget 300M!

 

Would you really recommend spending $1,500 on axle shafts to toss into a factory D44? Not being a smart ass...just curious. I'm changing all my shafts right now to prepare for slabs and 37's. I'm going with Ten Factory front and rear. Hopefully those combined with front gussets and dynatrac ball joints will last until I go D60/D80.

 

No... Everyone wastes money in there own ways though. Just throwing out another option wich is highly sought after in hi performance scenarios.

 

I was going to go with the tens like I have on my front. I believe they are 4130? I forget

 

1541h in the rears ibelieve. The fronts are 4340.

Edit :Just looked they list rears at 1541h or 4140 depending on application.. If i were to order id specify the 4140 if you can

 

Got ya. I was just curious the track record of the 300M vs. other shafts in factory housings and carriers. Been using 300M in my hot rods for years. My Vette constantly broke rear shafts until upgrading to them

EDIT: posted before I read the rest. The rear D44 axles for JK's are 4140 from Ten. Just went through this last week when ordering mine.