A method for manufacturing a banjo-type drive axle housing for a motor vehicle is disclosed. The first step is the operation of forming the substantially identical upper and lower half members having a U-shaped cross-section along entire length thereof with radially extending wall sections. Each of the members is metal formed, such as by stamping or forging, from a blank sheet of steel. Next step is to select a desired box-section of an axle beam portions, and a desired size of an opening in a central portion of the axle housing. Then, if necessary, the wall sections of the housing half members are trimmed so that when assembled said housing half members provide the desired box section and size of the opening in the central portion of the axle housing. Finally, the trimmed housing half members are welded to each other to produce the axle housing.
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