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Old 11-30-2013, 01:01 PM   #1
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Rear truss options?

What are my options for a rear truss on an 05'LJ Rubicon? I've come across the TNT and BlueTorch Fab. Any others?

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Old 11-30-2013, 02:39 PM   #2
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Old 11-30-2013, 02:42 PM   #3
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Artec doesn't make one for the TJ/LJ, at least I haven't found it if they do.
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Old 11-30-2013, 04:59 PM   #4
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Synergy makes a great 1/4" DOM inner axle sleeve kit that really strengthens & stiffens it up.

SYNERGY MANUFACTURING*::*Jeep JK*::*Synergy Jeep JK, TJ/LJ, XJ, ZJ D30/44 Inner Axle Sleeve Kit
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Old 11-30-2013, 05:10 PM   #5
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Synergy makes a great 1/4" DOM inner axle sleeve kit that really strengthens & stiffens it up.

SYNERGY MANUFACTURING*::*Jeep JK*::*Synergy Jeep JK, TJ/LJ, XJ, ZJ D30/44 Inner Axle Sleeve Kit
Rear Jerry, not front.
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Old 11-30-2013, 05:14 PM   #6
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Rear Jerry, not front.
Damn I knew it was for the rear, I googled inner rear sleeve & that's what came up & misread that info. I was thinking inner sleeve, not inner axle shaft sleeve. I'll have to look again, I know inner sleeves are available for the rear D44.
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Old 11-30-2013, 05:24 PM   #7
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Damn I knew it was for the rear, I googled inner rear sleeve & that's what came up & misread that info. I was thinking inner sleeve, not inner axle shaft sleeve. I'll have to look again, I know inner sleeves are available for the rear D44.
While sleeves add some beef to the tube you don't gain any strength at the pumpkin where it's really needed plus I plan on installing some 35 spline chromoly shaft and I'm afraid there would be interference.

I've come across one produced by Terraflex that looks to be the best out of the bunch. While I like the engineering behind the blue torch fab setup I would have to find a new home for the Riddler dif cover.
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Old 11-30-2013, 05:31 PM   #8
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Old 11-30-2013, 05:32 PM   #9
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To my way of thinking, a 35 spline shaft has no business in a D44 size axle.

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Rear Jerry, not front.
Now that I do more searching, it appears sleeves are easy to find for the front D30/D44 but not the rear D44. That's a curious thing, I found a few threads asking why they can't find the sleeves for a rear D44 either. I read an article recently in Crawl Magazine, I think, that mentions installing sleeves in the rear axle tubes. I hope I can find it tonight or tomorrow.

All I can think of is the rear D44's OE tube has a vent threaded into it but it'd be a no brainer to drill a matching hole in the sleeve.
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Old 11-30-2013, 05:43 PM   #10
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Old 11-30-2013, 05:49 PM   #11
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Old 11-30-2013, 06:55 PM   #12
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To my way of thinking, a 35 spline shaft has no business in a D44 size axle.
Why is that?
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Old 11-30-2013, 07:16 PM   #13
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Why is that?
For the same reason you don't run a 50 amp fuse for your CB radio. I'd rather snap an axle shaft than bust up the ring or pinion gear.
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Old 11-30-2013, 08:07 PM   #14
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For the same reason you don't run a 50 amp fuse for your CB radio. I'd rather snap an axle shaft than bust up the ring or pinion gear.
Ok, with that line of thinking I shouldn't beef up anything because the next thing down the line is going to break.

While I somewhat understand your logic there are ways to beef up the gear set as well. I intend on building the factory equipment to the best of its ability. There will always be something to fail as there will always be guys breaking Dana 60's. When I have 10 grand to drop on some tons then maybe I can move that direction. Until then I will strengthen everything I can as funds allow.

A little common sense goes a long ways when it comes to wheel'n with a heavy foot.
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Old 11-30-2013, 08:36 PM   #15
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Ok, with that line of thinking I shouldn't beef up anything because the next thing down the line is going to break.

While I somewhat understand your logic there are ways to beef up the gear set as well. I intend on building the factory equipment to the best of its ability. There will always be something to fail as there will always be guys breaking Dana 60's. When I have 10 grand to drop on some tons then maybe I can move that direction. Until then I will strengthen everything I can as funds allow.

A little common sense goes a long ways when it comes to wheel'n with a heavy foot.
Don't try to change what I said. I never said strength upgrades were a bad idea, I said 35 spline shafts would be a bad decision for a Dana 44. Personally, I'm running hardened alloy 30 spline Superior Axle Evolution alloy axle shafts front and rear in my rock crawling TJ & I have considered but ended up rejecting 33 spline shafts in the rear. So I believe in beefing up axles but not beyond what the axle and its gears can handle.

Not to mention I'd also be very interested in how you can beef up the ring & pinion gears as you said is possible.

So again, and in my personal opinion, 35 spline shafts would be a bad decision for a Dana 44. If you actually need 35 spline shafts because you're breaking 33 spline shafts, you need a bigger axle than a Dana 44. Simple as that.
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Old 11-30-2013, 09:06 PM   #16
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Don't try to change what I said. I never said strength upgrades were a bad idea, I said 35 spline shafts would be a bad decision for a Dana 44. Personally, I'm running hardened alloy 30 spline Superior Axle Evolution alloy axle shafts front and rear in my rock crawling TJ & I have considered but ended up rejecting 33 spline shafts in the rear. So I believe in beefing up axles but not beyond what the axle and its gears can handle.

So again, and in my personal opinion, 35 spline shafts would be a bad decision for a Dana 44. If you actually need 35 spline shafts because you're breaking 33 spline shafts, you need a bigger axle than a Dana 44. Simple as that.
Not trying to change what you said in the least. Can you provide some numbers as to actual strength of alloy axles vs gear sets so that we may substantiate these thoughts?

Don't get me wrong, I'm new in the Jeep world and just trying to wrap my head around as much information as possible. I'm gathering parts as we speak to tear apart both axles and build them. Right now I'm running 35's and would like to make a move to 37's or possibly 39.5's. My plans are as follows:

-D44Front-
-Artec truss with w/Johnny joint UCA mounts
-Artec Inner C gussets
-RCV axles
-5.13 gear set (G2 or Yukon)
-ARB locker
-Riddler differential cover

-D44 Rear-
-Truss
-Alloy axles
-5.13 gear set (G2 or Yukon)
-ARB locker
-Riddler differential cover

With both of these axles I'm considering the Jantz engineering JANA K4 kit which would allow me to run the slightly larger JK gear set in the TJ D44. I'm also considering making a move over to the Reichard Racing knuckles to work with a full hydro PSC setup.

I want to make one run at this thing and build these 44's as strong as a 44 can be built and if they break deal with it at that time.
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Old 11-30-2013, 09:28 PM   #17
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When you start talking 37-39.5" tires, you're above where even built D44 axles belong. I'd be looking into more appropriate size axles like a 9", D60, 609, Currie, etc.

Here's a thread on Pirate with some additional opinions... will these axles hold up to 39" tires - Pirate4x4.Com : 4x4 and Off-Road Forum

Notice the D44 they described as marginal was on the front... and the front axle seldom ever sees more than around 50% of the stress the rear axle sees.
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Old 11-30-2013, 09:28 PM   #18
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^at that point you're polishing a turd to run 40s.

For that kinda money build some 609s and be done with it.
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Old 12-03-2013, 05:38 AM   #19
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Originally Posted by Jerry Bransford View Post
To my way of thinking, a 35 spline shaft has no business in a D44 size axle.
What if that 44 has an ARB and JK ring/pinion gears? What will break first now?

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Originally Posted by Jerry Bransford View Post
Now that I do more searching, it appears sleeves are easy to find for the front D30/D44 but not the rear D44. That's a curious thing, I found a few threads asking why they can't find the sleeves for a rear D44 either. I read an article recently in Crawl Magazine, I think, that mentions installing sleeves in the rear axle tubes. I hope I can find it tonight or tomorrow.

All I can think of is the rear D44's OE tube has a vent threaded into it but it'd be a no brainer to drill a matching hole in the sleeve.
"Sleeving" semi-float rear axles isn't a common practice since the sleeves would have to terminate short of the outer bearing surface. Therefore, you wouldn't be able to weld the ends and would only be able to use rosette welds. It's doable but increasing wall thickness doesn't do nearly as much as a truss in terms of bending resistance.
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Old 12-03-2013, 09:31 AM   #20
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That was the missing part I wasn't thinking of Imped, the outer bearings. Doh! Thanks, that makes sense.
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Old 12-03-2013, 09:45 AM   #21
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39s on a Dana 44 screams new balljoinys once a month to me....
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Old 12-03-2013, 10:58 AM   #22
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39s on a Dana 44 screams new balljoinys once a month to me....
What if that 44 has some form of 60 outers? For example, the late model Ford SD 60 ball joints are massive.

Besides, we're talking about rear axles. It's possible to build a super stout 44 that can hold up to 40" tires but it generally makes more sense to just go with a bigger axle.
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Old 12-03-2013, 12:25 PM   #23
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At the cost and time to mate 60 putters to a tj Dana 44 I think it would be cool but silly compared to just starting with a 60 in the first place. Lets also not forget that the tjs Dana 44 isn't on par with a Dana 44 you would find in a full size truck but instead a hybrid between a 44 and 30. Overall sounds like a cool project if yoi have the cash but for the same cash you could build something stronger.
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Old 12-03-2013, 01:14 PM   #24
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I don't disagree....just playing the devil's advocate, as usual.
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Old 12-03-2013, 01:39 PM   #25
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Would be interesting to see just how far you could push those axles before they become less 44 and more a hybrid of everything lol back on topic about a rear truss...have you considered just fabricating one and welding it on?
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Old 12-03-2013, 02:12 PM   #26
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OP, what are you doing that requires a truss? Are you moving away from the factory suspension configuration?
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Old 12-03-2013, 10:42 PM   #27
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What if that 44 has an ARB and JK ring/pinion gears? What will break first now?
That's the route I'm considering moving towards, the Jantz Engineering K4 kit. The only problem is I can't find many guys running it.

I've already ordered the Artec front truss with inner C gussets and RCV's for the front. Just need to decide on rear shafts and gear sets then I can order the ARB's. I have no doubt that 44's will hold up for quite some time with the way I'll be using it.

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OP, what are you doing that requires a truss? Are you moving away from the factory suspension configuration?
Nothing really, more or less piece of mind. At some point in the future I'm sure factory configuration will get modified but not right now.
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Old 12-04-2013, 12:02 AM   #28
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I run JK gears and an ARB in my TJ 44. I also run a custom triangulated suspension and, thus, it made perfect sense to cut all of the factory mounts off and go with a truss for the upper mounts. My truss ties into my diff cover.

So how do you plan to add a truss if you don't plan on removing the factory mounts?

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