Should be possible to find a new housing for $100. Swap the internals over later.
P.S.
North Smithfield Auto has a bunch of them for $100.
from what i remember when i bought it the person before me hit a tree in the woods and totaled the rest of the jeep. possible it was fatigued and me driving and wheeling on it over these last two years pushed it out of fixable range.
i guess now its time to figure out what the hell i’m going to do
i have torches 
outside of swapping housing components, an xj axle should bolt right in right?
ya, that is an XJ axle. HP D30 from a 99 i believe. too bad Gene still didnt have that XJ. i would have just taken the front end out of that thing.
I just orders gussets from Iron Rock Offroad. $50 including shipping. i will try to use a threaded rod, washers and nuts to try and compress the C back to the right size and then weld the gussets on. hopefully that keeps them in there right spot so i can put everything back together and at least have my truck back. not sure what i’m going to do from there. i can either get another D30 and swap in everything i have, trying to regear to use the ARB again or i have a line on a Waggy 44. build the 44 up over the summer and selling off everything i have that wont work. either way i have a boat load of work ahead of me and will probably not be able to wheel this season.
whta do you mean no wheeling, sounds like it could be a weekend project, maybe. i agree with eric that the upper part of the C looks to be f’d…which makes sense given what the camber looks like from your pics. if you plan to try to straighten using threaded rod, i’d recommend heating up the elbow of the upper C, and if you have gussets for the lower, i’d also weld those on first before beginning to straighten
just checked them out, they’re one piece
i’ll probably make gussets for the lowers to attach between the tube and the lower portion of the C before i try to bring the upper portion down to its correct spot. i dont want the lower to bent up in the process so whatever i can do to limit that type of movement i’ll do. i’m thinking i will just heat it up a bit with a propane torch just to equalize the temp in the steel but more so for the welding process. i dont want to fatigue the steel too much during the bending. i have some research to do before the gussets arrive. they are ordered and i hope to have them by this weekend.
If its bent then its already wasted. Trying to bend it back is a waste of time. Once metal yields it becomes much more brittle. Not only that, your chances of bending it back to the right position is about zero.
For $100 you can bolt in a different housing. Swap the ARB over later. We can have a tech day to set up the gears.
I’m inclined to agree with Eric here. Bolting in a new axle will probably take just as much time as messing around with your current one. Plus in the long run it’ll be stronger. What gears do you have currently?
410’s
damn it! makes sense to scrap it. if i went the new axle route i would want to do the regear right away while its out instead of dicking around with trying to regear while its under the Jeep. hopefully this snow melts after the rain today and i’ll run up to see about a new housing. i have the gussets on the way so i will just put them on the new axle. i’ll probably need a hand picking up the new housing if anyone is available in the next day or 2. Krissie is working today so i’d like to go get one tomorrow. I WISH I HAD A FREAK GARAGE! I cant even temporarily put this thing together at is point to try and get it somewhere, the camber is down right dangerous. looks like its going to be another Condo parking lot axle swap… surprised they haven’t flipped on me yet about this thing.
did i ever mention i’m very indecisive
If you need some to give you a hand tomorrow let me know, not super busy at work, i can take a “cough cough” sick day
im around today, i know you said krissie was working. i was thinking of heading up that way to run an errand anyway
Pretty full schedule tomorrow but I could slide out at 4:00 which should be enough time to make it to North Smithfield auto. They have at least 6 HPD30’s listed on car-part for $100.
When you call them make sure the price does not assume a “core charge” for your old axle. They are notorious for that. It should not be a big deal to swap over the ARB. I think Ricky said he had some D30 setup bearings. Beside that all we need is a dial indicator, a honking torque wrench, and some extra shims.
I think Ricky has everything but the torque wrench.
I have a regular torque wrench and might be able to get my hands on a super one from my old work but will need to talk to someone. think HF has a BIG torque wrench? what does it need to be rated for? ahhh i guess i’ll have to check the write up on Pirate. i’ll work on getting everything i need during the day tomorrow. i’m hoping i wont need to do much massaging of the shims. in a perfect world it will be a direct swap… LOL so basically i’m screwed
About 250 ft-lbs.
I have a 1/2 drive click type torque wrench that should be sufficiant, give me a ring if you want it.
Derrick, if ya could get some one to trailer it up here you can use my garage- 1 car ,air tools ,jacks stands. should have everything you need or I can get it, ecept dial indicater. I built my whole jeep in it. AJ