my left rear axle tube is bent up about 3/4" (from the housing to the flange)on my dana 44. I just noticed when I pulled my entire axle out of my 93 YJ to intall new gears because I sheared off several pinion teeth.I allready have a master install kit with new bearings, seals, pinon, ring, etc. My questions are:
would a bent axle tube cause a pinion to fail (pinion broke on the street under little load) [/*] why do the splines look perfect on my axle shaft if it is operating at such an angle[/*] and would the carrier be damaged (I have an ARB)[/*] Does anyone have a used or cheap d44 housing (I have cherokee width now.) [/*] is bending the tube back an option [/*] home made trussing ideas [/*]

Replace entire housing or Retube housing with thicker tubing. Add a good truss on top.
If you are worried about re-using parts, have them inspected, or install em' and run it. Or sell everything you got and go bigger.