Quick update:
Rode Hot Springs with the Louisiana crew Memorial day and other than a sliced tire on the first trail of the day, the Jeep did well and there was no damage or needed repairs. I ran my spare the rest of the day which worked fine. The tire was sliced on the sidewall and I purchased the tire from 4WP with the warranty, so I took it back to 4WP on June 1 and as of today (6-29-21) 4WP still has not replaced the tire, they state there is no tires available due to Covid.
On 6-26-21, I did a day trip to Hawk Pride and sheared off all 5 wheel studs on the rear DS axle, see the write up on that trip here:
Hawk Pride day trip
It was a hard day on very slick rocks (especially on Merlin) and the Jeep took a good beating, but still performed well. Post ride inspection shows the following:
-Body damage on the rear pass side fender and the front pass side fender (see above Hawk pride link for pictures).
-Currie Drag Link is bent, pushing the Tie Rod clamp back into the steering stabilizer (which was punctured and all oil drained).
-Rear Axle Passenger side Upper Control Arm Bracket is cracked (this is the last remaining OEM axle side control arm bracket left, all others have been previously replaced).
-Need to inspect the axle flange which had sheared the wheel studs to ensure it is straight and then replace the wheel studs.
-The wheel studs on the other rear axle (passenger shaft) look like the threads are flattened, so I will replace those wheel studs and all the lug nuts on all 4 wheels.
-While on Merlin I had some thumping coming from the trans tunnel area, when the front axle was articulated, so I need to investigate that.
-Normal undercarriage scrapes and dings, but nothing looked like it was of concern.
I am basically using this post as a checklist for the above items which I will have to get fixed before heading on my next trip in a few weeks.
I already pulled the rear axle out in prep to install the new upper control arm bracket. Since I will need to pull the one axle back out to reinstall my chromoly axle after I replace the wheel studs, I am also going to go ahead and flip the calipers in prep to doing a shock outbd this winter. I already have the upper control arm mount and I have the BMB wizard brackets for the parking brake when flipped.
The good thing about a Dana 44 is that it is pretty easy to pull and man handle yourself, throw it on a few furniture movers and you can wheel it all over with no issues. That lightness is also what limits the Dana 44.