Demon Powersport PAXL-6094XHD-3.5 X-Treme Heavy Duty UTV CV Axle Shaft 4340 Chromoly Long Travel

The Demon Powersport PAXL-6094XHD-3.5 is the brand's flagship X-Treme Heavy Duty CV axle, engineered from the ground up for high-performance off-road and racing applications. Built to exceed the capabilities of their standard Heavy Duty line, this axle is constructed entirely from 4340 Chromoly steel — shaft, housing, cage, race, and balls — and subjected to a proprietary dual heat treatment process for maximum strength and longevity.

The 4340 Chromoly construction provides superior elasticity, allowing the axle shaft to absorb drivetrain stress internally rather than transferring it to the differential and surrounding components. Internal components are micro-polished to reduce friction and heat buildup, while high-load Molybdenum grease provides smooth, low-friction lubrication throughout the CV joints.

Demon's re-engineered cage design delivers components that are 20–30% larger than their standard Heavy Duty line, with a unique boot design using Thermoplastic Polyester Elastomer (TPEE) — stronger, stiffer, more fatigue-resistant, and more temperature-resistant than standard OEM boots. The axle's double-plunge design allows the inboard joint up to 1.5 inches of plunge travel and 40° of articulation, while the outboard joint travels 0.5 inches and swings up to 47° — preventing binding even under extreme suspension travel.

The 3.5-inch variant (PAXL-6094XHD-3.5) is purpose-built for use with long travel suspension kits and lift kits. Compatible suspension brands include Cognito Motorsports, Fireball Racing HCR, NXS Designs, Madigan Motorsports, SF Raceworks, Lone Star Racing, Fifty6 Industries, FabWerx, Long Travel Industries, and more.

Key Features:

• Full 4340 Chromoly steel construction — shaft, cage, housing, race, and balls
• Proprietary dual heat treatment process for superior strength
• 20–30% larger components compared to standard Heavy Duty axles
• Re-engineered CV cage design for enhanced durability
• TPEE (Thermoplastic Polyester Elastomer) CV boots — puncture, fatigue, and temperature resistant
• High-load Molybdenum grease lubrication
• Micro-polished internal components for reduced heat generation
• Inboard joint: 1.5 in. plunge travel, up to 40° articulation
• Outboard joint: 0.5 in. travel, up to 47° swing angle
• 300M shaft option available for select fitments
• Compatible with major long travel and lift kit brands
• Precision CNC machined
• Backed by a 2-year limited warranty

Trusted by racers competing in BITD, SCORE, SNORA, and other top-tier off-road racing series, the Demon X-Treme Heavy Duty axle is a race-proven, direct-fit upgrade for builds running larger tires, increased power, or extended suspension travel.