It's no secret that the front Dana 44 in JK Rubicons is flawed. The tubes and inner knuckles are weak and the ball joints aren't up to snuff. Poly Performance has developed their comprehensive axle fix for the JK Rubicon 44 frontend. While they don't offer the ball joints yet, the rest of the housing's problems are cured. Here's what they say . . .
Here is our solution to the bending prone JK front axle housing. We cut out the stock tubes and brackets, sleeve the OD with 3 x .250 chromoly and weld on new HD track bar, lower control arm and shock brackets and housing truss and inner C gussets. We also rotated the pinion up to correct the front drive shaft pinion angle to eliminate front drive shaft vibes. Here are some other key features:
3" x .250 chromoly is 73% stronger in bending that the stock axle tube 3/16 HD lower control arm bracket with 1" higher control arm adjustment
HD track bar bracket allows for stock track bar location or 3" higher for using a flipped draglink
HD lower shock brackets that are relocated outward for shock to frame clearance under extreme articulation
Pinion is rotated up 8 degrees for correct front drive shaft angle
Inner C gussets to prevent inner C bending
We will be selling this as a do it yourself kit with laser cut DOM tube to lay over the stock tubes or offering a retube service in house using chromoly tubing. You will not be able to change the pinion angle with the DOM laser cut tube though. Price for the in-house re-tube will be approx $800 plus shipping and the do it yourself kit with laser cut DOM tubes, brackets and detailed instructions will be approx $500.