A dumb D35 question.

[8594]

By way of introduction let me ask a dumb question that my searches have not turned up an answer to.
1994 4.0L,5spd, Duff 3", Exp 8.8/Disk rear Arb and 4.56, the gears are new in this build.
The question is the Right front axle that I took out of the truck, cleaned up and replaced the U-joints in, will not fit back into the truck. It is about 3/16 or so to long. The inner axle is up against the oil seal in the diff and the slip yoke is fully compressed. As I said the only new part is the U-joint and it is the correct PN, fit nice, etc... Everything else axle wise is what came out. Could there be something with the Diff after the gear change?
Anyone ever seen this one, cauz I sure haven't.

Stumped in Oregon.

 

[UrbanRedneckKid]

Not sure if it's your issure or not...
I snapped a shaft in my d35 and replaced it with one from the j-yard. Had the same issue, my spindle wouldn't seat all the way. I noticed the seals were different, the one on the outter shaft behind the spindle, I swaped them from my snapped shaft to my new one and it was fine.

Other than that the only thing I could see holding it back would be if you did a c-clip eliminator with and internal spring and the spring was too long.

Good luck with it, it's probably something stupid.

 

[bigpotato555]

the same axle won't fit back in is hole???...that kind of weird...maybe there is some part of side gear laying around in there...

 

[8594]

Not sure if it's your issure or not...
I snapped a shaft in my d35 and replaced it with one from the j-yard. Had the same issue, my spindle wouldn't seat all the way. I noticed the seals were different, the one on the outter shaft behind the spindle, I swaped them from my snapped shaft to my new one and it was fine.

Other than that the only thing I could see holding it back would be if you did a c-clip eliminator with and internal spring and the spring was too long.

Good luck with it, it's probably something stupid.

Right now I'm feeling stupid!
But it is out beyond the seal in this case.

 

[8594]

the same axle won't fit back in is hole???...that kind of weird...maybe there is some part of side gear laying around in there...

I'm starting to wonder... It's crazy, or I am...
The inner axle is pushed into the seal in the Diff and the slip yoke is bottomed out...
If it was a side gear I doubt that the axle would push completely into the seal.
I am wondering if the seals are in the right sides of the Diff. One seal is flat and one concave. Which one goes into which side
No, I didn't do the gear swap, and it has been just long enough that I don't remember, not that I really looked.

I'll check in the AM to see what the morning crew has to say.

 

[Hahnsb2]

Concave seal goes on the drivers side.

 

[stegomon]

i had the very same problem once i put in locker in my diff.....so i ground down the axil....no probles since

 

[8594]

i had the very same problem once i put in locker in my diff.....so i ground down the axil....no probles since

Open diff in the front.
The axle is bottomed out against the seal.

 

[8594]

Well, it turns out that Mother Ford may be the cause for this one.
In 94 they started playing with parts and I have learned that there is another seal, which is not the standard one everybody stocks and puts in their kits...
Of course no one so far has one, and I have yet to track down the part number only the info that... there is another seal.

 

[4x4junkie]

I haven't seen a difference in diff seals myself... Is the seal not letting the shaft splines fully engage into the differential side gear? (end of the shaft against the differential cross shaft?)?

Is the truck up on a hoist and the suspension hanging at full droop while you're doing this?

 

[8594]

I haven't seen a difference in diff seals myself... Is the seal not letting the shaft splines fully engage into the differential side gear? (end of the shaft against the differential cross shaft?)?

Is the truck up on a hoist and the suspension hanging at full droop while you're doing this?

The seal is "installed" correctly.
The shaft slips right in until the seal contacts the larger diameter area of the shaft... Or the shaft is stopped by the seal.
The truck is on jack-stands, and suspension position has no effect, it is not correct at full droop ride height or full compression...

 

[4x4junkie]

Sounds like maybe you got a completely wrong seal then. The shaft should have a wear mark on it from before. If the shaft isn't going in at least that far, then that's likely where your problem is.

 

[metalmacguyver]

Umm, the suspension position had better have an effect on weather it fits. If it doesnt fit with the suppension at ride hieght, when that droops and the slip joint needs to contract, it wont be able to will bind and break.


If you remove the spring on the drivers side and jack the beam up, how much space is there between the passenger side pivot bracket and the differential?

 

[8594]

Sounds like maybe you got a completely wrong seal then. The shaft should have a wear mark on it from before. If the shaft isn't going in at least that far, then that's likely where your problem is.

Wrong seal.
That is what I'm thinking it goes in PAST the wear pattern and is not in far enough.

 

[8594]

Umm, the suspension position had better have an effect on weather it fits. If it doesnt fit with the suppension at ride hieght, when that droops and the slip joint needs to contract, it wont be able to will bind and break.


If you remove the spring on the drivers side and jack the beam up, how much space is there between the passenger side pivot bracket and the differential?

Nothing with the beams or mounts was changed, so whatever the clearance with the Duff lift that was there before, is still there.
The only new parts in the front end are:
Ring & Pinion + Install Kit (including Seals)
Ball Joints.
Universal joints.
Paint.
It all fit before the tare down, and the drivers side is perfect!