on the housing mass = strength comment. Why does the 44a use Aluminum behind V10's and LS engines? Why is the new Currie Rock Jock and Aluminum housing? Again, bigger isn't always better. I could careless if I break something. Heck I intentionally try for failures. This is my racer mentality.
Why breaks something for the fun of it? Do you have that much money that you can afford to? Or are you just breaking other peoples stuff?
Aluminum housings are a totally different story. Again, this fits into the category of alloy of metal used. Those Currie housings and the 44a housing are both very thick aluminum, and very high grade of aluminum at that. Aluminum is actually stronger than steel in many respects, it however does not have the same fatigue life. I'm talking about cast iron and cast/extruded steel when talking about 8.8 vs D44 vs D35 housing strength. A D60 is much heavier than an 8.8 or D44...and much stronger. In general, more material to support stress = more weight and more strength. Sure you can make a lightweight 9", truss it, put 40 spline alloys in it and it will be 1/2 the weight of a D60 and twice as strong, but not many people have a budget for that.
Can't change your mind, don't really care too either. Good luck with your 8.8
Don't need an 8.8, I've got a D44
your responses are examples of "it's what the books said would work" thinking. Not that it's bad, it's a different approach to problem solving than the way tinkerers experiment.
I'm a tinkerer. But I'd rather tinker with an educated guess than simply tinker with something for the hell of it. I'd rather run an 8.8 or D44 vs a D35 or S35. Each have their plus and minus, but for where the money goes, I'd rather spend it on something I know is going to last and take abuse.
Originally Posted by never monday
so why is it a weaker housing than the TJ 44?
Originally Posted by mrblaine
What makes you think the D-44 doesn't flex?
Never said it wouldn't flex. Just saying it won't flex as much as a D35 housing when under the same stress. And similarly, the 8.8 won't flex as much as a D35 when under the same stress.
That said, hopefully we all know the D44 uses the same tubes as a D35, so the tube flex portion of this 'housing flex' is kind of subjective. The TJ D44 is kind of a 'hybrid D44', like the Rubicon front D44. This makes the TJs D44 less strong than a Ford or Chevy 3/4 ton D44, or even the JK HD D44. We do know however, the walls of the cast housing are thicker in a D44 than the D35, and there is more ribbing built into the D44 housing than the D35 housing. Hopefully, as you know, these mean the housing is stiffer, and therefore flexes less.
As you know, when you get flex you start to move parts. When you move parts, tolerances become extremely important, and you can break parts due to interference, in addition to the shear strength of the axle shaft itself.
You can add to a D35: alloy shafts, truss, c-clip eliminator, add high quality gears, retube the housing with .25", etc, but its going to cost a lot of money and work. Wouldn't it be smarter (and more economical) to just buy an axle that already has the strength you're looking for?