Dana 44 Conversion, Tie Rod, and Steering Question

[Bufante]

First off, thank you all for your help, this forum has been a tremendous resource for a newer Jeeper!

I scored a Dana 44 out of TJ Rubicon to put into my TJ (replaced the Dana 30). It appears as if the previous owner of this Dana 44 drilled out the knuckles to 5/8-thus eliminating the taper for the original tie rods to attach to. I have found some inserts to get the taper back, with a little welding. I have been given the idea to replace the knuckle and now I am considering just replacing the whole steering system to something more beefy.

So my question is, what would you do? I’m already over budget on this project lol, but I would prefer to do it right so I don’t have to do it again. This is a daily driver and a medium trail rig (will be one of these days lol). If I can be fine with a cheaper solution, then I’d go there. But like I said, I want it be ready to rock if need be, not looking for a band aid. I just don’t know enough to know what is adequat. TIA

Photo is with stock tie rod for reference.

 

[hosejockey61]

New (used) knuckles is probably your best option. As far as a tie rod, if you aren't into heavy rock crawling you should be able to get by with the ZJ tie rod. It's a solid bar unlike the hollow stock tire rod. It won't break the bank. If you plan on heavy rock crawling I would suggest Currie one ton steering.

 

[Kid Mechanic]

You’ll get new knuckles with your Big Brake Kit from Black Magic. You know you want the BBK!