1 of 16
TMR Axel Tube Sleeves
1. JK front axle fully stripped and all our holes marked to be drilled then plug welded. We installed our knuckle gussets previous to the sleeve install.
2 of 16
TMR Axel Tube Sleeves
2. We like to use a paint marker and straight edge to measure out and mark our holes. Be sure and drill at least 4 or more holes on the short axle side and 6 or more holes on the long tube side.
3 of 16
TMR Axel Tube Sleeves
3. Our TMR kit came with the inner tubes, which are made from 1026 DOM Tubing beefing your axle tubes up by 60%. The kit also comes with the “C” knuckle gussets.
4 of 16
TMR Axel Tube Sleeves
4. Check out the thickness of my tube and note the delicate finger placement.
5 of 16
TMR Axel Tube Sleeves
5. We drill 1/4” pilot holes and then go back over and open the holes up to 1/2”. This allows for good penetration for your plug weld.
6 of 16
TMR Axel Tube Sleeves
6. Be sure and deburr the axle tubes, so sliding the tube sleeves in goes smoothly. A light tap from a rubber mallet works well for the install.
7 of 16
TMR Axel Tube Sleeves
7. Long side tube going in, don’t forget to tap it in the sleeve, you want the sleeve flush with ORG tube.
8 of 16
TMR Axel Tube Sleeves
8. Another shot of the tube sleeve
9 of 16
TMR Axel Tube Sleeves
9. Man that’s a thick tube.
10 of 16
TMR Axel Tube Sleeves
10. This is where your sleeve should sit when installed properly. Now we are ready to weld.
11 of 16
TMR Axel Tube Sleeves
11. Other side.
12 of 16
TMR Axel Tube Sleeves
12. Outside of the tube welded.
13 of 16
TMR Axel Tube Sleeves
13. All holes fully plug welded.
14 of 16
TMR Axel Tube Sleeves
14. Short side holes fully plug welded.
15 of 16
TMR Axel Tube Sleeves
15. Back side of the axle, holes fully plug welded.
16 of 16
TMR Axel Tube Sleeves
16. All stitched in. Ready to reassemble the internals.
Off-Road Addiction
It’s as easy as 1....2....Sleeve
If you own a 2007 to current Jeep JK Wrangler 2 Door or 4 Door, then sleeving your front axle should be on the top of your mods list. These axles may look beefier than the predecessor TJ axles, but they are not - these tubes are prone to bending even with mild, off-road use.
We called upon our good friends at TMR Customs who sent us their Front axle inner sleeve kit, to help us out. Our project was a Dana 44 front axle from a 2010 JK Rubicon (but don’t worry, they also have a kit for any Dana 30 users.)
I will outline the steps involved for properly installing this kit. The job is above a basic skill level to tackle at home or even a hobby shop, so if you are uncomfortable attempting this install please know that Off Road Addiction performs this on a daily basis and would be happy to help.
First off, be safe. It’s best if you have a hoist, but if you don’t then get some jack stands and secure the Jeep. You will need to totally disassemble the front axle. Start by removing the wheels, brake calipers and rotors. Remove the tie rod ends and drop the steering out of the way so it is easy to get to the differential. To save some time, remove the three wheel-bearing bolts with the wheel bearing attached to the axle (don’t forget to unclip the wheel speed sensor). Once that has been done, it’s now time to drain the differential fluid and remove the diff cover. Remove the case bearing caps on both sides and pull out the case with the ring gear. If you have a Rubicon, remove the electrical connector for the lockers - it is located on the top of the differential. Once the case is out and the axle housing is bare - it’s time to start marking the holes to drill. We locate the holes all the way around the tube. Some of the holes you can drill straight through the axle tube, particularly on the long side. Then, on to centre punching all the holes. After drilling the holes, the next step is to clean and prep all areas to be welded. Now we are ready to install the sleeves, short sleeve to short tube and vice/versa.
We are ready to weld up these bad boys, and we like to alternate front to back, side-to-side, top to bottom until you work your way through all the holes allowing the heat to dissipate. Next step is to weld the tube ends. Time to clean up any welds you don’t like and then hit the axle with some paint - we use flat back but pick what you want because it’s your rig and we won’t judge. With the paint drying, it is time to reassemble the internals of the axle. Quick tip for Rubicon owners - be sure to install the locker plunger before you install the case. Follow the disassemble steps in reverse for reassembly and now you have a JK front axle housing that is 60% stronger than stock. We sell and install all the TMR products, so if you have any questions or would like to purchase this product and/or have any other products installed please do not hesitate to contact us. www.offroad-addiction.com