JK DIFFS - thoughts from the SJC brains trust

So the JK has gotten a little tired after all the reccies and then Jambo. Front end is a little vague compared to before, a front axle seal has gone. We dropped a lower rear CA and man handled it back together at Jambo.

The suspension needs a check and re-align. We've chosen to use the damaged seal as an excuse to change ratios. Maybe we can squeeze a little more caster up front. Bearings should be done with the diffs?

What else should we be looking at or considering?

(If you're not familiar with the Jeep, it's a 2014 JK Rubicon, 3" lift, mostly Synergy, on 34.4s. 25k very much either trails or bitumen getting there and back. It's a trail specialist not a daily driver.)

If you are changing the diff ratios, you DEFINATELY want to allow the fitting of an an overhaul kit at the same time.
Before you pull it apart double check ball joints and hubs beforehand as these are easier to change at the same time.
Personally I'd beef the diff a little at the same time and fit some tube seals.

Wooders, that is fantastic advice, cheers. I've been digging through the Internet hunting for info that helps me understand. Your thoughts on the following would be appreciated.

1. Dana 44 front is much like a Dana 30, strengthening sounds advisable.
2. Dana 44 rear can probably be left alone?

Would you recommend C gussets as well?

The JK front D44 isn't what I'd call a real D44. Yes is a bit of a step up from the D30 but not much and not in the area thats the biggest issue - ie the axle tubes.
Bendind knuckles is actually pretty rare and IMHO if you've bent the knuckles a lot else will probably bend first. But reinforcing the tube relative to the knuckle is a good thing and thats where sleeves work well.

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You're a champ, Wooders.

thanx

Just another vote of thanks to Wooders. We ended up going a little further but I'd have been lost without the input.

We've chosen 4.88 ratios over 4.56 and will upgrade from 315/70R/17 tyres to a true 35x12.5. But not for a little while. Not all inner sleave options (to thicken the axle tubes) allow external seals (the seals are designed to fit the original internal diameter) but we found one.

We decided early on to include C gussets with new ball joints and ended up trussing the front diff as well. Over kill I suspect. Rear diff is the inner axle sleaves only.

Other minor work as well - check and tighten throughout, rear tire carrier adjust, winch wire to rope, brakes (drums had more mud than brake pad), diff breathers.

thanks to Sam at Hills for the work. Our list is starting to get smaller!