Dana 60 35 spline problem

[houdini]

I am installing a set of 10 Factory 35 spline stubs and Warn Premiums on my 79 Ford Dana 60 when I noticed the cap dial was very tight. its sticking slightly out from the cap body when the cap screws are tight.

I took the other 10 Factory 35 spline stub and compared it to a stock ford 30 spline stub and its just about 1/8" longer. I am guessing this is my problem. The inner shaft is all the way in the tube. The bearing adjustment nut and wheel bearing lock nut are installed correctly.

Anyone else ever run into this? How did you solve it?

I assume I can just shave a little over the inner part of the cap dial so it rest in the cap as it should?

Thanks!

 

[drkelly]

Not sure specifically about the 10 Factory shafts, but this is a common problem with aftermarket 35 spline stub shafts in Ford D60's. The typical solution is to just cut a little off. I have Superior stubs shafts in mine, and did not have this problem.

 

[houdini]

Thanks!

I hate to cut the shafts. I would think that would take off the part I need to hold the c-clip on the end. Any thoughts on trimming the dial?

 

[drkelly]

I've never heard of anyone modifying the lockout to resolve that problem. Maybe call Chase and see what he says. There have been a few threads on the subject over on pirate before.

Found one:
http://pirate4x4.com/forum/showthread.php?t=567269&highlight=ford+stub+shaft+long

 

[rockcity]

sounds like you have a Dodge/GM stub shaft as the Ford stubs are shorter than the Dodge/GM

 

[Cperry]

I was of no help evidently this is not an issue w/ drive flanges and we have not run into this before. That pirate article is a good read. They definetly arent GM stubs I wish they were b/c the chevy stubs are in short supply, fords are much more plentiful. Someone mentioned doing a race swap that will extend the spindle out, thats an option. But whacking it off and using a die grinder to cut a new groove seems to be the easiest way to go. They talked about using a lathe but the groove is not that critical I would just go slow and make it as straight as poosible by hand. If you need us to cut it on the lathe we can. also modifying the shaft won't void our warranty so no worries.

 

[houdini]

thanks chase....and everyone for the input.

i did shave about 1/8" off of the shaft yesterday. still left about 1/16" of spline before the grove for the c-clip or retainer. i did install it and it works better, but i need to pull it again and take some more off. the stub is pressed pretty good up against the inside of the dial and when the wheel spings in reverse it grabs the dial and auto locks the hub.

i'll read over the pirate article now.

 

[GubNi]

I use a cut off wheel on a grinder to make new rings for the clip when needed.