Dana 44 rear bent axle flange fix?

[multihull]

It appears that it is a very common issues that Jeep Wranglers bend their axles. Well what really happens is the axle flange buckles and bends (the round disc part that has the wheel studs on it). It is almost impossible to bend the axle shaft, the weak point is where the flange joins the axle shaft so the flange bend because of a big sudden shock or load on the wheel.
Now here's my thought, why not just straighten the flange. Basically the flange has a buckle/wobble in it so just identify what part dips in and what part dips out by rotating the axle while it's still in the diff housing and mark the two opposing point with a paint pen. Then remove the shaft then get a very big hammer and give it a massive hit the flange back into alignment. You can check if you've got it right by sliding the shaft back into the diff housing and give it a spin test. Or if you have a lathe use this for a spin test or you could even make up a simple timber test jig.

What do you think, crued or not possible?

The reason i'm thinking about this is I had a bent stock axle flange when I bought the car, I replaced it with a new Chromemoly set and all was good for two weeks until I drove out of Landcruiser Mt Park 4 weeks ago. The car was packed with camping gear, I was driving slowly on a OK dirt road within the Park and then I hit a big pot hole. The axle flange bent, only slightly but just enough to make one brake caliper squeak again. "7uck"

[MightyMouse]

The stock axles aren't very "bend resistant", most are just a simple press job and all is good again, although I've struck one that had to have the axle flange machined as it was a bit out.... not a lot, but it doesn't take much "out of true" on the flange to turn into a bigger issue at the disk.

Not keen on the "big hit" solution...... a lathe, dial indicator, press and V blocks are my weapons of choice.

[PLN]

Not really going to add anything here but is this what make that sqelching noise when turning corners and a slow to medium pace?

Actually i will add something. I agree with mighty mouse in that trying to smash it back into true is going to be near on impossible. A lathe, dial indicator, press and V blocks would be the way to go if anything.

[multihull]

I don't think you get my drift, it's not the axle that bends so you don't need a press and a V block. It's the flange that needs side pressure to take the buckle out of it. Yes I agree you need a massive hammer to straighten an axle and that's just not going to happen.
I just want to hit the flange on the side, now that would happen with a strong sharp blow.
Has anyone in Brisbane got an old Dana 44 rear axle with a bent flange that they want to lend me and I'll test my theory? I thew my old one out.
Be brave and think out side of the square, that's why I drive a Jeep.

[MightyMouse]

Of course I could be wrong but I think you might find that the bend is actually in the axle but just right out near the flange.
Its obviously impossible to straighten with the bend there so skinning the flange it is the only solution.

You obviously shouldn't hit it that hard with the axle fitted as you could damage the wheel bearing, if your taking it out... then just fix it properly.

Anyway.... hope it works out.

[multihull]

Originally Posted by MightyMouse

Of course I could be wrong but I think you might find that the bend is actually in the axle but just right out near the flange.
Its obviously impossible to straighten with the bend there so skinning the flange it is the only solution.

You obviously shouldn't hit it that hard with the axle fitted as you could damage the wheel bearing, if your taking it out... then just fix it properly.

Anyway.... hope it works out.

Definitely don't hit it when in the axle housing.
I'm going to try the experiment and keep you posted. I just need an experimental axle shaft that has a bent flange. I'll keep you posted.
Who has a spare axle? I sound like a Nutty Professor or Physassist. LOL & again LOLer............

[Hayesio]

I bent my stock rear axle flange couple of years ago. It bends right where it connects to the shaft, so effectively the flange is still flat, the axle is still straight, but the flange is on the piss. I've done exactly the same thing in other cars too. I've always just replaced them with upgrades axles.

I think you would have your work cut out for you straightening it with a hammer - you would be more likely to bend the flange disc out of flat. Doubt you could get it true enough anyway even if you could avoid bending the flange. The only possibly feasible way I would attempt is to make a jig to hold the axle vertical in a press and offset it to the press head so you could work the outer of the flange. You would need a good hydraulic press, 50 or 60 tonne.