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1994 Jeep YJ Welding Axle - Wrecking Yard YJ

Ditching The Dana 35
By Pete Trasborg
1994 Jeep Yj Welding
After we found what Currie Enterprises charged for cutting down an axle and axleshaft, we were sold. This is our short-side shaft in the CNC mill getting resplined.

Ford 9 Inch Axle Diagonal View
We settled on a later-model Ford 9-inch axle from a pickup. That got us 31-spline axleshafts, big axle bearings, a stronger housing than earlier models, and the most aftermarket support of any differential.
Ford 9 Inch Axle Axle Part Zoomed
Another possible problem is some of the older axles weren't heat-treated enough to safely cut new splines into. The first picture is a Currie axle with plenty of depth to the heat-treating, and the second is our stock axleshaft with just enough depth.(continue)
Ford 9 Inch Axle Axle Part Zoomed 2
Unfortunately, the only way to figure out if the axle was heat-treated right is to cut it to length and look at the depth. Currie Enterprises does this as part of the service.
1994 Jeep Yj Broken Axle
We didn't think anything of the surface rust on the axle, but after getting it home from the junkyard and getting the brakes off of it, it was clear that this thing hadn't moved in quite a while. The drums were cracked, the springs were too rusted to use, and the adjusters seized. Save yourself some money and check before leaving the junkyard.
1994 Jeep Yj 31 Spline Axleshafts
The 31-spline axleshafts are tapered toward the ends, which means about 4 1/2 inches of axle needs to be cut off before it can be resplined.
1994 Jeep Yj Axle Welding
After the housing is straightened, the end is tacked back on and then welded in this jig. After it is fully welded, the axle is again checked with an alignment bar and straightened if necessary. Not bad for $100.

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1994 Jeep Yj Welding Ford 9 Inch Axle Axle Part Zoomed 1994 Jeep Yj Broken Axle
Ford 9 Inch Axle Diagonal View Ford 9 Inch Axle Axle Part Zoomed 2 1994 Jeep Yj 31 Spline Axleshafts

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