After reading about spun axles on the rear Dana 44 on JKs I took a look at the plug welds on my housing and they look like they are starting to separate at the edges. To address this issue people typically weld the axle tube to the housing around the flange.

However, I was thinking about taking a different approach. There are two large sight holes on the back of the differential housing, this would be a very convenient place to add some rosette welds. I have tried to look for examples of people doing this mod online and I cant find any examples for this specific axle. Do you think its a bad idea?

 

Are you talking about the holes where the case spreader would engage?

 

Ah is that what they are for? From a google image search I can say yes, those are the holes I am talking about.

 

I'll bet that's not the axle tube you see at the bottom of those holes. They don't look deep enough.

 

I’m pretty sure it is. I have seen people use them to sight in the axle after it has spun. Although, if it is going to make re-gearing difficult or impossible I can see why they are not used for this purpose.

 

There was a guy here years ago who spun the tubes pretty well which prompted me to go take preventative action....though I didn't have the traction devices he had. I just went right where the tube meets the housing. You'll accomplish the same thing, it'll just be on the outside. I've had them welded up for a while now and don't see any cracks or separation or anything like that.

As mentioned, the larger holes are for a case spreader. The smaller ones, about the size of a larger eraser are the factory welds.