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Cracked front rubicon dana 44 that has been sleeved and gusseted

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Old 05-16-2012 | 03:01 PM
  #11  
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That really sucks! Sorry to see that hapen. In looking at the picture I noticed the holes for the rosette welds on the sleeves are aligned vertically. This seems a great way to create a failure point. Was that what the sleeve manufacturer recomended? I'm no engineer but the housing cracked right bewteen two holes. Hope you get it fixed soon.
Old 05-16-2012 | 03:38 PM
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Originally Posted by wheelman2925
That really sucks! Sorry to see that hapen. In looking at the picture I noticed the holes for the rosette welds on the sleeves are aligned vertically. This seems a great way to create a failure point. Was that what the sleeve manufacturer recomended? I'm no engineer but the housing cracked right bewteen two holes. Hope you get it fixed soon.
I agree. I have always seen the holes stagered. I would check what the instructions said and then go talk to the installer about a replacement if he did not follow the instructions.

Either way, I would not weld it back up but would sugest a replacment as the crack is radial aboit the tube and looks to be close to 50% of the diameter. Even if you got the crack welded up good and added some plate across the crack, you would never get a good alignment as you would not be able to get it perfectly straight.
Old 05-16-2012 | 03:51 PM
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Originally Posted by JKbender
I agree. I have always seen the holes stagered. I would check what the instructions said and then go talk to the installer about a replacement if he did not follow the instructions.

Either way, I would not weld it back up but would sugest a replacment as the crack is radial aboit the tube and looks to be close to 50% of the diameter. Even if you got the crack welded up good and added some plate across the crack, you would never get a good alignment as you would not be able to get it perfectly straight.
X2
Old 05-16-2012 | 03:56 PM
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I was not wheeling when this happened... I'm running 37" km2's with 17" eagle alloy rims, and a 3" lift
Old 05-16-2012 | 06:26 PM
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Here are some more detailed pictures, what are your guys thoughts on this?
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Old 05-16-2012 | 06:28 PM
  #16  
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Dynatrac, I saw you chimed in on this, what are ur thoughts on it?
Old 05-16-2012 | 06:42 PM
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I'm no welder but I thought the same as others that they should have never put the plug welds together and I would think the shop that installed it should have to fix it or pay to replace it. I have never sleeved or saw one done but to me I would think the plug weld should be at the other end to keep the sleeve pinned into the housing but I may not know jack sh@t.
Old 05-16-2012 | 06:51 PM
  #18  
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Yea that sucks they did it wrong your supposed to drill the holes length wise not like that and the top weld doesn't even look full. The only thing I can think of is weld it like you do pipelines but that would shorten it a bit cause you'd have to cut it.
Old 05-16-2012 | 06:57 PM
  #19  
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Looking at the new photos it looks like the plug welds did not attatch to the housing. If anything the holes and possibly heat from welding directly contributed to the breakage. From what i've seen the housing tends to crack at the lca mount. Once again good luck. Perhaps a pr44 is in your future.
Old 05-16-2012 | 07:01 PM
  #20  
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Too me it seems like the plug welds should be staggered...



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