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Thread: Strengthing the LJ Rubicon front Dana 44.

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    ParaJeeper JeepinSoldier's Avatar
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    Default Strengthing the LJ Rubicon front Dana 44.

    A few months ago, the LJ got to the point where it just was not safe to drive. The brakes were marginal with 33's, and when I went to 35's they got downright scary. The front driveshaft had a bad case of angry sparrows, and the Jeep was a total dog with the 4.10's/42RLE/35's.

    Something had to be done, so I bit the bullet and got the Jeep to a shop. After much research and many phone calls, the Jeep went to Steve at JeepsExtreme in Fredericksburg. While there the LJ got EVO axle sleeves, 5.13 gears, new pinion yokes, front driveshaft rebuild, and a custom VANCO big brake kit. In the next few posts Ill detail the EVO axle sleeves.
    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    ParaJeeper JeepinSoldier's Avatar
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    The front Dana 44's in Rubicon TJ/LJ's are actually 44 centersections with 30 tubes and inner C's. Plenty strong for 31's and light wheeling, but I already bent one wheeling hard on 33's. As I dont have mega bux for a Dynatrac Trail 44, strengthening the axle I already have looked good to me. Enter the EVO axle sleeves.

    The sleeves slide into the stock axle tubes, then are rosette welded into the tubes and welded to the inner C. Various places claim a 30 to 60 percent increase in tube strength. I spoke to EVO and others and the consensus was that the sleeved axle should handle some pretty hard wheeling on 35's. As I dont plan on going bigger - this should work.

    More info on the EVO sleeves is here: http://www.offroadevolution.com/stor...prod=EVO-44MAG

    Install into a JK is here. The TJ is the same except I diddnt gusset the inner C's:

    http://www.jk-forum.com/showthread.p...Magnum-Install
    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    ParaJeeper JeepinSoldier's Avatar
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    To install, the axle is stripped, then holes for the rosette welds are drilled in the axle. The holes are cleaned out and then the tubes are slid into the axle. The rosette welds are welded into the holes, and the tubes are welded to the axle where they exit at the inner C. The EVO tubes are machined inside at the outer end for seals. Pretty trick!

    The axle sleeves:

    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    ParaJeeper JeepinSoldier's Avatar
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    The holes drilled for the rosette welds:


    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    ParaJeeper JeepinSoldier's Avatar
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    Sliding the sleeves into the tubes:



    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    ParaJeeper JeepinSoldier's Avatar
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    Steve doing some welding magic:
    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    ParaJeeper JeepinSoldier's Avatar
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    The finished sleeves:



    05 LJ Unlimited Rubicon. RE 3.5" short arm lift. 1" body and motor mount lift. 35" BFG M/T KMII's. 5.13 gears. Skid row and Jeep Medic belly up skid plates. Rokmen and Jeeperman bumpers. PSC rockers and full corners. Line X'd interior. Warn 9.5ti. Dual batteries. Dual tops. Snorkel. Full and half doors.

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    Thanks for sharing! Seems like a good investment for $160 to strengthen the Rubi axle.

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    Okay, dumb question but how did they get the metal chips from the drilling of the holes out of the axle tubes with the axle still in the jeep. Also what do you think of the new brakes compared to the stock ones. Are the brakes worth the money? Also how do you like the tall gears on the highway, you must be turning some pretty high RPM's at say 65 or 70 miles per hour.

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    Senior Member HillBillE's Avatar
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    Quote Originally Posted by C130Hilgy View Post
    Okay, dumb question but how did they get the metal chips from the drilling of the holes out of the axle tubes with the axle still in the jeep. .
    The center section (diff) is pulled. So you can use air, flush them out, or run a rod with a rag through, like cleaning a shotgun.

    I've made a couple of tools for dragging mud and crud from the axle tubes while the diff is still in. But with the diff out, it's a straight shot to push a rag through.


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