In our last story, by installing the newly released TEN Factory Chromoly Axles from National Drive Train, we were able to increase our Dana 44 shaft strength by as much as 30 percent. This is a must for anyone running 37s on a JK. But what about the other weak points that the JK Rubicon front Dana 44 has exhibited in more extreme situations? We have seen axle tubes bend and break, as well as knuckles that were so distorted they gave the Jeep the camber of a desert race truck. These are two areas that need attention when running big tires and the toughest trails … and Mt. Logan 4x4 has addressed them both with its new Sleeve and Gusset Kit for the Dana 44.
The sleeves are 3/16 DOM tubing that has been turned down to exact specifications, allowing them to slide into the factory Dana 44 axle tubes to make them twice as thick and similar in size to a Dana 60 tube. If you have slightly bent axle tubes, you will likely need a press to get the new sleeves in. However, we did not run into this unfortunate situation. The sleeves are left 0.5 inches short of the factory tubes, allowing space to remove the inner axle seals easily when necessary.
Picture 1: The plug welds are made after drilling multiple holes throughout the factory axle tube.
Before sliding the sleeves in, the Mt. Logan directions call for multiple holes to be drilled in the Dana 44 tubes in fairly specific locations and then to be plug-welded to the sleeves (above). Please note: Care must be taken to remove any debris and metal shavings that enter the axle tubes when drilling, and before the installation of the sleeves. We used a combination of magnets on a telescoping rod and clean shop towels to clean things up. Lastly, at each end of the tubes, the sleeves are also welded in for an extremely solid setup.
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You can see where the sleeve ends are welded to the tubes. It is a tight fit so be sure not to allow your weld beads to become too large.
Adding these sleeves was a simple process and only took a few hours, with most of the time being taken up by disassembly of the brakes, unit bearing and axle shafts. We’d say that even a green wrench could do it, as long as they are a quality welder … or bought enough doughnuts or beer to lure one over.
Addressing the bend-prone JK front knuckles is as easy as welding in a small gusset between the axle tube and the knuckle itself. The Mt. Logan gussets are nothing more than small pieces of steel that have been cut and shaped to fit into this tight location. We had to use a pry bar to scoot the coil spring over a bit to make room for the gusset but it required very little effort. Once we got the gusset seated in the correct position, it was welded in solidly from both sides. The gussets are not as beefy as a few others we’ve seen on the market, but we do think they’ll stand up to anything we’ll encounter, as well as the reality of many of us JK drivers that are mounting up 39 and 40 inch tires. John Williams at Mt. Logan 4x4 can report that many of his customers running 39’s and 40’s have had no tube or gusset failures using their kit while wheeling the most extreme trails in Moab.
The knuckle gussets fit perfectly and they almost look like a factory piece of the axle after being welded in. You can also see another plug weld just beneath the spring perch.
The Mt. Logan Sleeve and Gusset Kit is a must have for any JK that is running 37-inch-or-larger tires. It just might be the single most important upgrade you’ll make to your marginally strong Dana 44 front axle. Don’t get caught without it!
For information on Mt. Logan Off Road, contact the company at 435/752-4272 or visit www.mtloganoffroad.com.
