JK Dana 30 front "issue"

[gt6star]

The front axle tube broke on my JK unlimited X just inside the right lower control arm weld. Previous to this happening I was'nt able to get the Jeep aligned properly, at first the dealership tried to sell me an offset ball joint to fix the problem. The mechanic even told me that I may have a slightly bent axle tube and that it was ok...that was a few weeks after I picked it up brand new. Now my jeep is 2 years old with 64000 miles under it. The axle broke while driving on smooth graded dirt road. I didnt hear a pop or any noise, the only indication I got was the steering wheel turned one way and the jeep went the other. The dealership of course wont cover this under my Lifetime Powertrain Warranty, even though it was a known condition. I'm getting an entirely new axle housing, I'd like some advice/info on preventing this from ever happening again. I'd also love to hear if anyone else has had problems with this.....

[Black_ZJ]

Truss the housing, and sue the stealership. I assume you have all the paperwork for the previous work that caused the problem. And learn how to work on your Jeep.

[thetanningman]

I've heard of this happening on other forums with people running big tires and really abusing their Jeeps but it doesn't sound like you were abusing yours. What size tire you running? A Dynatrac ProRock 44 would fix your problem, stronger than a factory 44 or 30 housing. There are a couple companies that have sleeve and gusset kits out for a factory 30 also.

Good Luck,
p

[smbisig]

I have heard this issue is becoming common unfortunately. I know a lot of people are sleeving the tubes to gain extra strength. You would have thought Jeep learned their lesson with all on the bent D30/35 housings in the previous models.

[JPK]

Since you have to replace your axle tube and maybe your axle as well, I would take the opportunity to upgrade to a Rubicon D44, or, depending on your off road style, maybe an enhanced D44 - though it doesn't sound like you need to go that far. You may find an oem Rubicon D44 on Amazon or craigslist cheap as a take off or purchase on new.

Here is a link to Dynatrac, which as prviously mentioned sells upgraded D44's and also oem Rubicon D44's. In addition, they have a nice and informative write up of the advantages of the new generation Rubicon D44's. http://www.dynatrac.com/

FYI, I running an oem D44 with 37's, 4.88's and the AEV Hemi conversion and haven't had any issues in 22.5k miles. I don't go nuts off road and my rock crawling - not a lot of it - is as slow and smooth as I can make it. If I ever bend the tube it will be the Dynatrac Pro Rock upgrade for me.

Have you thought about contacting your insurance carrier? Slim chance but you might have coverage, at least for the tow to the dealership. And I'd be all over that dealership and working with Jeep customer service.
apparently there was something wrong with that axle tube from day one.

Edit to add that I wouldn't bother sleeving a D30, not when there are bolt on solutions available.

Also added: This might be the ideal time to regear if you've been thinking about it!

JPK

[cruiseroutfit]

Mount Logan 4x4 in Logan, Utah has been doing sleeve kits on the JK's since they first hit the market, it didn't take too long to find the inherent weakness with the tubes. Sleeve the axle or invest in something a little more stalwart i.e. Dynatrac, Teraflex, etc.

[gt6star]

Thanks for all the replies! The insurance covered it, thankfully, and the dealership was very quick with the work. They started wed afternoon and I picked it up thursday afternoon. Total bill for the Job was $2560 I paid my $500 deductable, new front axle housing (dana 30) new ball joints, seals, etc etc. The gears and axles were moved from the old housing. I'm only running 33" BFG AT ko's and do more exploring than rock crawling. I'll be looking into sleeving, trussing, gusseting this axle in the coming weeks. Just for refference does anyone know if a D44 bolts right up, or are there different control arms, tie rods yadda yadda yadda...?

[JPK]

The Rubicon D44 bolts right up.

There are options on the Dynatrac axle housings, you can select one that bolts right up or a custom configuration... But an option that bolts right up is available.

It's unfortunate that you didn't take the opportunity to use the insurance money for a D44. But now that you have an all but new front axle set up, it would be cheaper to sleeve it.

I would not spend the $'s to gusseett the C's. If you think its neccesary, first do a search for bent C's before you spend the S's. There are no first hand examples to be found. Dave h., owner of AEV pointed this out on his forum.

JPK

[smbisig]

Looks like they are sleeving the JK D44's too. http://www.quadratec.com/products/16356_100X_PG.htm