Off Road Evolution Jeep JK Wrangler
C2 Front Axle Reinforcement Gussets

June 3, 2008 Cindy Drivetrain Mods, Jeep JK Write-Ups 9


 
 With the Jeep JK Wrangler practically built to fit 35″ tires or bigger right out of the box, it really is no wonder that this is exactly what many JK owners have already done with their Jeep or are planning to do in the near future. Unfortunately, there is a minor drawback in going bigger that a few of us are starting to see and that is the front axle C’s will start to bend.   As it would seem, the front axle C’s on both the Dana 30 and Dana 44 front axles are somewhat weak and the strain from running bigger tires will be enough to bend the C’s to the point where a measureable and visible amount of camber to one or both front wheels can be seen. And, while some adjustment can be made to correct this with offset ball joints, this adjustment is limited and will not prevent bending of the C’s in the future. So what can one do to prevent this from happening? Install a set of Off Road Evolution C2 Front Axle Reinforcement Gussets on your Jeep today!Available for only $89, the Off Road Evolution C2 Front Axle Reinforcement Gussets are made out of 3/16″ laser cut and CNC bent steel and are designed to seriously beef up your Jeep JK Wrangler’s front axle C’s. These gussets do require welding but any certified welder should be able to install these in about 2 hours or less and for a cost of about $200.  Being that the axle C’s are made out of 1045 forged steel, you will not have any problems welded the gussets onto them.The following write-up details the steps necessary to install a set of Off Road Evolution C2 Front Axle Reinforcement Gussets.

What you will need

• Off Road Evolution C2
Front Axle Gussets
• MIG Welder
• Welding Mask
• Welding Gloves
• Drill or Die Grinder
• Wire Wheel Brush
• Rags
• Water
   
   

Installation
This photo shows what the Off Road Evolution C2 front axle C gussets will look like right out of the box. The pair in the distant are the upper halves and the pair up front are the lower halves.
1. The lower halves of the Off Road Evolution C2 front axle C gussets are CNC bent into shape but will need to have its seams stitch welded before they can be installed 2. This is a shot of what the lower halves of the Off Road Evolution C2 front axle C gussets look like after their seams have been stitch welded. 3. Elevate the front end of your Jeep JK Wrangler, remove the front wheels and then prepair the surface of the axle C’s and axle tube using a drill or die grinder with a wire wheel brush.
4. Check the fit of your new Off Road Evolution C2 upper front axle C gussets. You may need to use a hammer to tap it into place. Verify that all the areas you will need to weld are clean of any paint. Remove gusset and clean the area more if necessary.
5. Tack weld the Off Road Evolution C2 upper front axle C gussets to your Jeep JK Wrangler’s front axle C’s.
6. This is a shot of what your Off Road Evolution C2 upper front axle C gussets should look like after being tack welded in place.
7. Working on small lengths at a time with frequent breaks in between, begin welding the Off Road Evolution C2 upper front axle C gussets to the top of your Jeep JK Wrangler’s axle C. It is critical to NOT do everything all at once as it will create too much heat and will compromise the grease in your your ball joint and/or damage it.
8. In between welds, use some rags soaked in water to cool your Jeep JK Wrangler’s ball joint and areas of steel that you’ve just welded as shown in this pic.
9. This is a shot of what the Off Road Evolution C2 upper front axle C gusset will look like after you’re done welding it to the top of your Jeep JK Wrangler’s front axle C.
10. Check the fit of your new Off Road Evolution C2 lower front axle C gussets. As before, verify that all the areas you will need to weld are clean of any paint. Remove the gusset and clean the area more if necessary. 11. Tack weld the Off Road Evolution C2 lower front axle C gussets in place. 12. This is a shot of what your Off Road Evolution C2 lower front axle C gussets should look like after being tack welded in place.
13. Once again, making sure to work on small lengths at a time with frequent breaks in between, begin welding all the other edges of your Off Road Evolution C2 upper front axle C gussets to the upper half of your Jeep JK Wrangler’s axle C. It is critical to NOT do everything all at once as it will create too much heat and will compromise the grease in your your ball joint and/or damage it.
14. In between welds, remember to use some rags soaked in water to cool your Jeep JK Wrangler’s ball joint and areas of steel that you’ve just welded as shown in this pic.
15. Repeat steps #13 and #14 with the lower half of your new Off Road Evolution C2 front axle C gussets.    16. Apply some paint to your new Off Road Evolution C2 front axle C gussets and then reinstall the wheels back onto your Jeep JK Wrangler’s front axle.

And that’s it!! The front axle C’s on your Jeep JK Wrangler have now been beefed up to the point where they can withstand the strain of 35″ or bigger tires as well as any abuse you can throw their way on the trail.    Please let me know if you have any questions.

Installed Photos

To see more photos of what the Off Road Evolution C2 front axle C gussets look like installed, click on the link below:   Off Road Evolution C2 Front Axle
Reinforcement Gussets Photos

 

9 Comments

  4. where can I get the new ball joints?? I have spent alot of money getting my JK the way I want it, so why stop now!!!!!!!!

  5. why would they bend due to increasing tire size? You’re not increasing the mass or weight of the JK itself. I would guess that only hardcore wheelin regardless of tire size could effect the C’s to bend…

  8. Ive been driving up very large, steep concrete walls/barriers with my JK. I upgraded the gearing to 5.13 and run 37s aired down a bit to get some good leverage. I think my Cs are bent to hell but I cant tell just by looking. I was hoping someone might know what it looks like or acts like when the Cs do bend. I know Im having severe alignment issues and refuse to drive the poor thing.
    If its the Cs I assume i need to have them cut or get some crazy adjustable ball joints. After that Ill definately go with Evo’s gussets.

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