Dana 35 Steering knuckle stud options?

[94CRanger]

Hi All,

First time post, so don't slam me if this isn't where this should go. Plus, I haven't found much info on this and was wondering if anyone has ever had this issue or heard of a safe solution. I have a 94 3.0L 4wd and am in the midst of replacing the upper and lower balljoints, and here's what happened

I went to torque down the nuts that hold the spindle to the steering knuckle and, like a rookie apprentice, over torqued the nut and snapped the steering knuckle stud. I've checked local auto parts stores, online, and local auto wreckers and I can't even seem to find this gen of ford trucks with the Dana 35 to steal the knuckle, let alone the studs, from. I also tried a steering knuckle stud from a Dana 44 and the splines near the head of the stud didn't taper like the Dana 35 stud does, so it just floats around in hole where the stud goes (not a tight fit).

So my question, has anyone ever tried or heard of people using an alternative bolt & nut hardware (Grade 8 or better), or press-in studs from another gen of trucks?

I'll continue to search for another driver-side knuckle, or stud from a Dana 35 knuckle, but I would like to hear if anyone has heard of or tried a different solution.


Thanks,
Chris

 

[94CRanger]

Here are a couple photos of the stud & nut together, and a measuring tape to give a rough idea of the dimensions.

You can see how the splines of the stud are a bit fatter than the threads, that seemed to be the only difference between the Dana 44 stud (not shown in the photos) & the Dana 35 stud (shown in both photos). Plus it's a tad longer, but not the issue.

 

[JMF661]

I wouldn’t think you would have a terribly hard time finding a D35 equipped 90-97 ranger in a junk yard somewhere to swipe a few knuckle to spindle studs from.

The appropriate Bronco II may have the same studs as well. I’ve never worked on one to compare the two. I’m sure someone else here will chime in.

it’s possible a stealership could have the studs for order. I would imagine they would be difficult to come by at any run of the mill hardware or auto parts store.

Edit: In the tech section there is a spicer parts list for the D35 TTB. Spicer part number 42775 is the hex bolt you are looking for, I believe.

 

[scotts90ranger]

I broke one too at one point, but I have a spare axle to pillage from... but '91-94 Explorers are another source of parts...

 

[JMF661]

Totally forgot about explorers for a minute! Tons of those around.

 

[94CRanger]

Hey thanks for the replies.

Yea the dealership I went to said that the studs were discontinued and couldn't get them in. Same goes for the local auto parts stores.

I had a hard time finding any Rangers, Explorers, or Bronco II's within a couple hours of where I live. I did manage to find 2 Rangers about 5 hours from where I am, so I took a road trip and snagged couple studs and spare parts. Problem solved!

 

[scotts90ranger]

Which Vancouver are you in? If Washington there's always Rangers and Explorers in the You Pull It in either Sherwood Oregon or Foster Rd in Portland off of 205