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Old 11-25-2015, 01:42 PM
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To gusset or to not gusset

K I could be spelling it wrong but what's everyone's opinion on gusseting the front axle ?

I have 3.5 jks lift and 35x12.5R20 tires. Friend down the street from me installed the teraflex gusset kit and looks to strengthen the axle housing alot. He swears it drives better . Any input for a newbie ?

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Old 11-25-2015, 01:49 PM   #2
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I don't personally think it drives better, but yes def gusset IMO. I gusseted and trussed my front dana 44. Cheap insurance against bent C's or a smiling axle tube or worse. If you can weld then its a piece of cake to do so. If not I cant see a shop charging a whole lot to weld it up for you.

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Old 11-25-2015, 01:54 PM   #3
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The choices aren't "to gusset or not".

The choices are:

1. Gusset it now and it will hold up for many years (if done properly).
2. Let the axle bend. The "when" is only a matter of how you drive the Jeep.

Just do it. I'm sure the Terraflex kit is good. Another alternative is the Artec kit which is very popular. I've had the Artec kit on my Jeep since I switched over to 35" tires. It's holding up just fine, even with wheeling some substantial trails on a somewhat regular basis.
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Old 11-25-2015, 02:00 PM
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Thank you for the replies.

Ok so if I gusset can I do this on the truck ?

I can weld no prob . It would help if I don't need to disassemble
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Old 11-25-2015, 02:05 PM   #5
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Yes, you can do it without pulling the axle off the Jeep. That's how mine were done.

Be aware that welding the C gussets on can damage the plastic liners on the stock ball joints. It really seems to be hit or miss. My balljoints went out about a month after putting my gussets on. Could have been coincidence, but you never know.

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Old 11-25-2015, 02:22 PM   #6
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Thank you for the replies.

Ok so if I gusset can I do this on the truck ?

I can weld no prob . It would help if I don't need to disassemble
Like anything else, taking the axle off the Jeep so you have room to maneuver, along with being able to rotate it makes it a lot easier. I was doing a whole bunch of work on my Jeep when I did the gussets (and the truss) so we just pulled the axle off while it was mostly apart anyway. But there's nothing stopping you from welding it all while it's on the Jeep. Once the tire is off, there's enough room to get in there to weld it.

Really, it's just 4 bolts for the control arms, one for the track bar, the swaybar end links, the drag link, brake calipers, shocks, and ABS sensors. But there's nothing wrong with leaving the axle in place.
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Old 11-25-2015, 02:25 PM   #7
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Gussets are very inexpensive. Might as well swap out those cheesy factory ball joints, if you have them, right after those gussets cool down from the welding.
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Old 11-25-2015, 06:03 PM   #8
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I pulled my front diff by myself in just under an hour. Much easier to work on.
As others have said, you may as well order new balljoints and instal them at the same time.
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Old 11-25-2015, 06:23 PM   #9
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Gusset and do the ball joints at the same time. You can leave them in, wrap wet rags around them to keep them cool but as long as you've got it all torn apart, just get it done.

And gussets won't do anything for your axle tubes. They reinforce your inner C's. On the JK D44, the C's are pretty weak. If you want to reinforce the axle tubes, you need to sleeve or truss them. Probably overkill with 35's unless you're playing in the rock a lot.
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Old 11-25-2015, 09:19 PM   #10
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Originally Posted by "flyfishnevada;22687793"
And gussets won't do anything for your axle tubes. They reinforce your inner C's. On the JK D44, the C's are pretty weak. If you want to reinforce the axle tubes, you need to sleeve or truss.
Ok I have a question for you. Have you actually seen a JK D30 or D44 bent or just the tube bent at the C welds (which the C gusset supports as well). I have seen tubes bent at the C but I have yet to see an actual C bent. Even a Google search provided no such evidence. I have asked this question on many forums and no one yet has provided proof of photos that the JK D30 and D44 C's bend.
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Old 11-25-2015, 10:14 PM   #11
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Ok I have a question for you. Have you actually seen a JK D30 or D44 bent or just the tube bent at the C welds (which the C gusset supports as well). I have seen tubes bent at the C but I have yet to see an actual C bent. Even a Google search provided no such evidence. I have asked this question on many forums and no one yet has provided proof of photos that the JK D30 and D44 C's bend.
I don't have any photos but two people in my Jeep club have had bent C's in the last month or two. One was a D30 on 33's, the other was a Rubicon D44 on 37's.
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Old 11-26-2015, 07:43 AM   #12
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I went with gussets and an Artec Truss and am very happy.

D30 running 37's and 50K miles.
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Old 11-26-2015, 08:20 AM   #13
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I don't have any photos but two people in my Jeep club have had bent C's in the last month or two. One was a D30 on 33's, the other was a Rubicon D44 on 37's.
One of the guys in the area thought it was a good idea to jump his jeep in a gravel pit. Didn't turn out well. But again C's themselves didn't bend, tubes bent right at the C weld.

Non the less it is a good idea to sleeve and gusset or truss the factory diff housing.
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Old 11-26-2015, 05:54 PM
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Getting artec truss kit done this Friday . 465$ installed . I'll keep everyone posted. Thank you to everyone for the posts
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Old 11-26-2015, 07:12 PM   #15
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Remember that if you are doing a drag link flip to order the raised bracket with the Artec kit (which also raises the swap bar link mount). I flipped when I did the truss.
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Old 11-26-2015, 07:33 PM   #16
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Makes 0 difference driving, but now I dont worry about bending an axel or a C ..
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Old 11-26-2015, 09:54 PM   #17
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Plan on doing mine...want the extra insurance. Like it's been said above I'm doing the ball joints and going a step further and doing regear, Trutrac, Rcv axles, Reid racing knuckles etc
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Old 11-27-2015, 06:14 PM
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Remember that if you are doing a drag link flip to order the raised bracket with the Artec kit (which also raises the swap bar link mount). I flipped when I did the truss.
Mines already flipped with JKS lift I did
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Old 11-30-2015, 12:31 PM   #19
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I have minimal lift so I'm looking at the Synergy front axle assurance kit that XT is selling. Has C gussets, axle sleeves, lower arm skids, and new axle seals
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Old 12-04-2015, 09:07 PM   #20
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Gusset. It's cheap insurance for what could be an awfully expensive repair.



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Old 12-05-2015, 06:21 AM   #21
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K I could be spelling it wrong but what's everyone's opinion on gusseting the front axle ?

I have 3.5 jks lift and 35x12.5R20 tires. Friend down the street from me installed the teraflex gusset kit and looks to strengthen the axle housing alot. He swears it drives better . Any input for a newbie ?
Take a look at these guys too, quality parts and good prices.
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Old 12-05-2015, 07:17 AM   #22
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I'm still waiting to see a picture of a bent C. Can't help but think it may be the elusive Unicorn of the JK world. Everyone has heard of it and a very few have seen it but no pictures seem to exist. As a metallurgist I can't imagine them bending as stout as they are unless they were significantly abused but I have certainly heard of it.
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Old 12-05-2015, 08:17 AM   #23
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It seems like the actual concern is a bend in the tube or joint where the C meets the tube, not the actual C itself.
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Old 12-05-2015, 09:00 AM   #24
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Google "jeep bent c" then click on images tab. On first try it found over 15 legitimate pics, and many non-relevant ones. You must not be looking very hard.
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Old 12-05-2015, 09:20 AM   #25
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Originally Posted by dvn4life1972 View Post
Google "jeep bent c" then click on images tab. On first try it found over 15 legitimate pics, and many non-relevant ones. You must not be looking very hard.
As far as the JK ive not seen or read many actual cases. Some of the pics are people thinking they are bent and posting for confirmation. I bet most are bad joints. I still think adding gussets is cheap insurance so i recommend them.
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Old 12-05-2015, 09:27 AM   #26
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Originally Posted by dvn4life1972 View Post
Google "jeep bent c" then click on images tab. On first try it found over 15 legitimate pics, and many non-relevant ones. You must not be looking very hard.
As far as the JK ive not seen or read many actual cases. Some of the pics are people thinking they are bent and posting for confirmation. I bet most are bad joints. I still think adding gussets is cheap insurance so i recommend them.
In the pics that have a bend, it's like the other guy said...the tube bends at the C. There are several of those. Pretty much all of the gussets strengthen that area.

And I completely agree. Gussets are cheap insurance. Very DYI- able too for many folks.
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Old 12-05-2015, 12:59 PM   #27
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Google "jeep bent c" then click on images tab. On first try it found over 15 legitimate pics, and many non-relevant ones. You must not be looking very hard.
Spent a lot of time looking on Google and other boards and come up with bent Cs on much older model D44 Cs but none for the JK D30 and D44.
And yes C gussets are cheap insurance and they do support the gusset to tube joint to prevent the tube from bending.
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Old 12-05-2015, 03:14 PM   #28
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Ok, I decided to buy the Artec gusset kit, but not until AFTER I replaced my ball joints. The replacement ball joints are Synergy, and here's my dilemma: should I remove the BJ's before having the gussets welded? I know the plastic stock ones will melt from the welding heat, but what about aftermarket ones like the Synergy's? I realize it would have been easier to accomplish while the BJ's were out, but my planning sometimes tends to be a little off. What do you guys think?
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Old 12-05-2015, 03:23 PM   #29
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Ok, I decided to buy the Artec gusset kit, but not until AFTER I replaced my ball joints. The replacement ball joints are Synergy, and here's my dilemma: should I remove the BJ's before having the gussets welded? I know the plastic stock ones will melt from the welding heat, but what about aftermarket ones like the Synergy's? I realize it would have been easier to accomplish while the BJ's were out, but my planning sometimes tends to be a little off. What do you guys think?
The C's can be welded on without danger to the BJ's. Just have to be patient and let it cool after a little bit of welding. Some say wrap it with wet rags, but I feel you're better off not building a lot of heat overall. Not difficult at all.
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Old 12-06-2015, 11:02 AM   #30
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I was hoping that would be the answer. There is MUCH to be said for planning upgrades in stages-properly planned stages! Thanks for the advice, I appreciate it!

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