I'm looking for some ideas as to why I'm going through the 5x4.5 hubs on my D44 way to fast. I had one break 15 minutes into wheeling Saturday after it was lettting go the entire trip down. The replacement started to go on the ride home. It's a TJ D44 with 4.88's and a Lock-right, turning 35's. I also broke this same side hub about a month ago on the street making a hard left hand turn, and the previous owner of the axle broke the same side in the same way I did Saturday back in April. I pulled the shaft, and it looks fine - not bent, twisted, etc. Any ideas of what could be causing this? I'm hoping it's not a bent housing...any other ideas? I'm going to call Warn soon but I'm not expecting much help from them.

Thanks.

Sounds like a tweaked housing to me. Something is obviously not straight...

Make sure the wheel bearing is not backing off the spindle. Some of the older 5 on 4.5 kits where breaking spindles. Warn has a new heat treated spindle and a new style locking spindle nut. Give them a call and ask for it, they should at least send the locking nuts for free.


Edit: I did not realize you were speaking of a rear d44 with a FF kit. I would still check out the spindles. If that is not it I would say bad housing too.

maybe you could get drive flanges for it im not sure though

If it only happens on one side you most likely have a bent spindle or housing. If you have something bent the usual tattle tails with the Warn floater are it will leak oil, the locking hub will disengage under power, and the axle shaft will rub on the inside of the spindle.

You really need to consider steping up from the 5x4.5 setup if you want a floater and go 5x5.5 so you can run stronger hubs or drive flanges. 35s, lockers and serious trail use will lead to lots of broken hubs and premature wheel bearing wear.

Thanks for the tips. Warn said pretty much the same thing as you all did, it could either be a bent shaft, messed up spindle, or bent housing. I'm still deciding on which it is at the moment.

Oh, I don't really want to step up to the 5x5.5 kit because then I'd have to change the front kit too, and buy new wheels. I haven't decided if I'm going to keep this kit or not - I may just go back to the semi-floater setup. I agree though - even in tip top shape, I'm going to be going through these hubs on an all-too-regular basis.

Anyway, thanks for the help.
:usa:

Low gears, locker, and 35's is why they are breaking. A guy in my club had that kit, and it did the same thing. The 5 on 4.5 kit cannot take it, it's simply not strong enough. There is a big difference between Warn's 5 on 4.5 kit and their 5 on 5.5 kit, and with the 5.5 kit you can buy the drive flanges. He is replacing the full-floater kit with Moser semi-floater axles. BTW, it wasn't a bent housing, it was a brand new Currie unit.

They were breaking because of a bent spindle and not perfectly straight shafts. I'm probably going to Moser's/Warn's/whatever instead, because I agree - this kit isn't up to running 35's. BTW, if anyone has some 44 shafts, email me ;)

i would bet with 35" tires those axle tubes are bending quite a bit as they are only 2 5/8" in diameter!

bent housing (are there any signs of leaking at the ends?) and I bet your running a manual tranny!

Originally posted by BlueJeep
Low gears, locker, and 35's is why they are breaking. A guy in my club had that kit, and it did the same thing. The 5 on 4.5 kit cannot take it, it's simply not strong enough. There is a big difference between Warn's 5 on 4.5 kit and their 5 on 5.5 kit, and with the 5.5 kit you can buy the drive flanges. He is replacing the full-floater kit with Moser semi-floater axles. BTW, it wasn't a bent housing, it was a brand new Currie unit.

ok here is my experience with this. I had a dana 60 FF built (5 on 5.5) and kept breaking the hubs...actually the hub nut inside of the hub cap (the part that engages and disengages the hub) kept bending. both sides. i replaced the nuts and it did it again. now this axel was brand new, never been offroad and i know the axel shafts were straight. the guy who built is spun it on a lathe and swears the housing was perfectly straight. I pulled the thing apart checked the bearings and they were properly tightened. Anyways i have since then gotten a set of drive flanges and have had no more problems. I talked to Jeff at MIT and he said that the warn FF hubs are really a weak point. anyways get some flanges. this should cure your problem.

While I appreciate the added help from you guys, I've already decided to go back to a semi float set up. There are no drive flanges for the 5x4.5 setup. If you read my last post, you saw that the FF components were the problem, not the housing. Thanks again.

PS - anyone have some D44 shafts they want to sell me?;)