Bent my front axle: Now what?

[Thunder Mass]

So it looks like I bent my front axle in Tillamook OR over Labor Day weekend. I'm invested in the Dana 30, with shafts and locker, so I guess I'm going to try to stay with that, as long as everything inside is still good. At first, I saw some TJ Dana 30s for sale in my area, but not so much right now. But before I commit to it, I first gotta ask if I should be looking at a direct swap with a low pinion, or look for a high pinion.

So it looks like my axle shafts and locker will transfer over, along with the brakes and steering. But, with a high pinion, I'd need a different ring/pinion. I understand that the high pinion is a bit nicer of an angle, and higher clearance. Maybe a bit stronger? But, besides the ring and pinion, does it bolt in directly to my Jeep? Would the driveshaft work? I have a 4" short arm lift, too. Just any XJ or ZJ?

Last is a truss, gusset, and sleeves, to help make sure this doesn't happen again. It seems like these aren't very popular here, and that if you need one, you probably did something wrong. Well, I don't plan on doing a Dana 60 just yet (someday...) and I don't know that I need a Dana 44, so I might as well make the 30 stronger, since I've already bent one. The truss and the gusset makes sense, I just wonder if they'll interfere with anything. Like my raised sway bar mounts; but that's a question for MrBlaine. I guess I kinda don't get the sleeves, how they go inside the axle.

Kinda sucks, trying to figure this all out while on the road. I appreciate any help.

 

[Grey_Machine7.3]

I'm just going to be that guy and ask for pics.

As long as your shafts n everything else aren't trashed get a used housing maybe. But I don't know much about any of that. I just want to see the Carnage

 

[Alex01]

When I bought my rubicon take off axles the front had a slight bend to it. I found a shop near me that works on large commercial trucks and government equipment. I brought the bare axle housing to the shop and they were able to put it on a lathe-like machine to spin it then use a press to straighten it to near perfect. If I recall it correctly it cost around $150-$200. An advantage to a method like the one I did was you don't need to pay someone to reset the gears.

 

[Thunder Mass]

I'm just going to be that guy and ask for pics.

As long as your shafts n everything else aren't trashed get a used housing maybe. But I don't know much about any of that. I just want to see the Carnage

The axle doesn't look that bad, but when you look at the springs and sway bar, it's obvious the alignment is way off; I'm sure they are related. but the wear on the inside of the tire is VERY bad, after driving it back about 250 miles.

I'll have to give you pics tomorrow. Way too dark now.

When I bought my rubicon take off axles the front had a slight bend to it. I found a shop near me that works on large commercial trucks and government equipment. I brought the bare axle housing to the shop and they were able to put it on a lathe-like machine to spin it then use a press to straighten it to near perfect. If I recall it correctly it cost around $150-$200. An advantage to a method like the one I did was you don't need to pay someone to reset the gears.

I'm a bit confused, did you remove the differential? That would be nice, to reuse mine. I'll have to see if I can find anyone in the area who can do that. There's also no guarantee the donor axles are straight, either.

 

[Alex01]

I'm a bit confused, did you remove the differential? That would be nice, to reuse mine. I'll have to see if I can find anyone in the area who can do that. There's also no guarantee the donor axles are straight, either.

At the time I still had the factory 30/35 under the jeep. In your case, you would need to remove the axle from under the jeep, remove the brakes, axle shafts, and pumpkin. It really isn't that bad of a job.

I got directed to that place by a reputable shop that does gearing in my area. If I was you I would contact a few offroad shops in the area and ask if it's something they could tackle or if they could point you in the right direction.

 

[Alex01]

This is what mine looked like prior to getting it straightened.

 

[Grey_Machine7.3]

I just want to say. That sucks. For both of you

It's freaking wild that that tiny of a difference could really grenade your axle. That's like a 16th of an inch, if even. Then again, I work with robots and I've literally seen them tear themselves apart because of an adjustment off of 0.25mm

 

[Goatman]

Most of the trusses I've seen are designed to fit without messing up your other mounts, or have new mounts integrated into the truss.

 

[Fouledplugs]

A full truss will definitely help the Dana 30. A high pinion is a swap that comes with added benefits, one being added gear strength and the other being more driveline clearance.

Some of the XJ and ZJ Dana HP 30’s are direct swaps.

Hopefully someone with a truss with a bolt on lift will chime in on the brand and clearance issues. Total guess, but Artec comes to mind.

 

[Igoo65]

You can do a yellow pages or Google search in your area for Driveline Specialist. They can usually straighten it. Good luck!

 

[Thunder Mass]

At the time I still had the factory 30/35 under the jeep. In your case, you would need to remove the axle from under the jeep, remove the brakes, axle shafts, and pumpkin. It really isn't that bad of a job.

I got directed to that place by a reputable shop that does gearing in my area. If I was you I would contact a few offroad shops in the area and ask if it's something they could tackle or if they could point you in the right direction.

I got a bit confused when you mentioned gearing.

Most of the trusses I've seen are designed to fit without messing up your other mounts, or have new mounts integrated into the truss.

I hope so, though I'll message Blaine about the sway bar mounts and gussets; that's what I'm thinking won't work.

A full truss will definitely help the Dana 30. A high pinion is a swap that comes with added benefits, one being added gear strength and the other being more driveline clearance.

Some of the XJ and ZJ Dana HP 30’s are direct swaps.

Hopefully someone with a truss with a bolt on lift will chime in on the brand and clearance issues. Total guess, but Artec comes to mind.

I think I'll try JCR for the front, but they don't seem to make a TJ Dana 44 rear. I'll probably have to go with Artec for that.

I'm not sure about sleeves, though. Don't make as much sense as a truss.

You can do a yellow pages or Google search in your area for Driveline Specialist. They can usually straighten it. Good luck!

That's a great option, but I think for the sake of time, I'll have to go with a donor. That said, what're the chances that that axle is bent too?

 

[Thunder Mass]

I appreciate all of the help. Still gotta figure out what high pinions fit, and then find a donor axle. I'm already on the road on a trip, and couldn't take much for pics. But I do have ones of the sway bar and springs, and the tire that's now worn pretty badly.

 

[jjvw]

What specifically is bent?

 

[Thunder Mass]

The passenger tube. I know the alignment is messed up too, but no real sense in fixing that until the axle is fixed.

 

[jjvw]

The passenger tube. I know the alignment is messed up too, but no real sense in fixing that until the axle is fixed.

How did you determine this? The pics posted only show a tire and that the axle might be off center.

 

[Thunder Mass]

Using a level, the tube was bent. Sorry, it was pouring rain and I had to get going. Gonna be gone for a week ish.

Yeah, the pics don't show much axle wise, other than it is definitely off center. Dunno how well you can see the tire, bit it is VERY worn on the inside, and the camber was 1.8. not sure what else could do that?

 

[U8MYDZT]

Using a level, the tube was bent. Sorry, it was pouring rain and I had to get going. Gonna be gone for a week ish.

Yeah, the pics don't show much axle wise, other than it is definitely off center. Dunno how well you can see the tire, bit it is VERY worn on the inside, and the camber was 1.8. not sure what else could do that?

Did you try to just get an alignment? I might be wrong but that doesn't look bent, nor does the measuring method look sound.

 

[John Scoggins]

Yeah, the pics don't show much axle wise, other than it is definitely off center. Dunno how well you can see the tire, bit it is VERY worn on the inside, and the camber was 1.8. not sure what else could do that?

Busted ball joint(s), bent knuckle...

You need to use a straight edge to determine if the tube is bent, like Alex05 shows.

 

[Steel City 06]

Go big or go home!
https://www.dynatrac.com/axle-assemblies/prorock-60-axle.html
A little more reasonable
https://www.northridge4x4.com/part/...rac-prorock-44-unlimited-tj-package-assembled