[quote=f5fstop]
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Originally Posted by Hummie2
Is there any manufacturers who produce a Cast iron or some other type of Steel housing? Yes, AAM makes the identical axle in cast iron
Just MY opinions on this issue
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The above is good info... that means there is a direct bolt in replacement made of what should be a higher strength (albeit heavier) replacement. I'm sure that the aluminum case was used for weight savings, but if its proven that case deflection is whats causing this issue, it was a bad choice.
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Originally Posted by f5fstop
I fought housing flex in certain Dana 44s (they are not all cast the same) before. Bottom line: when I reinforced the housing and stopped the flex(distorsion) I stopped breaking ring & pinion gears. I did the same, and I ended up busting axles. Every part of the drive train has a weak link, something will break if too much torque is applied with too much weight and too much restriction, in my Jeep it was the axle shafts. Personally, I would prefer the shafts, easy to replace in the field, and inexpensive.
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Any of us here who has seriously wheeled has broken more then our fair share of parts. I've busted R&Ps, 9" ford cases, bent housings, axle shafts, transfer case output shafts, driveshafts, etc. I eventually ended up with Dana 60s front and rear, then my axle problems went away (in that rig...
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