Axle spacer washer wearing.

[Lerad92explorer]

I have had quite a few B2's, early Ranger 4x4s and now my 1st Explorer. A 92 4dr 5spd, manual transfer case and manual hubs.
On any of my TTB Dana 28s never ever wore one out.
My Explorer on the other hand. I have gone thru 2.5 sets of those splined axle shaft spacers. Did gear/swaps from 3.45 to 3.73 about 2 years ago. All new bearings, seals, universal joints. The front Dana 35 center came out of a 93, along with the drivers side spindle and a few axle shafts were mix and matched between the 2 trucks because of better looking bearing/seal surfaces. My late brother who was a 35 year Ford Mech did the work, he actually worked on all my Ford's, hence why I'm asking on here instead of getting him to fix it.
No heavy 4x4ing. Hunting/logging roads mainly and I realize this has to get me back home so don't rat bag it. Running 30x9.50x15s.
Once hunting season starts and snow falling I do lock my hubs and basically leave them locked in. Done this with all my 4x4s.
So why is my Dana 35 Explorer so hard on these?

 

[SenorNoob]

Didn't the D28 have a thin plate with needle bearings that the spacer turned against? Vs the D35 just being a softer, thicker washer rubbing the end of the spindle...

 

[dvdswan]

Welcome to the site.

 

[Shran]

My opinion - Ford decided to be cheap on that part. The D28 style was perfect, those never wear out. But on the D35, if you leave your hubs locked in all the time, it is constant metal turning against metal. I never see worn spacers on trucks with auto hubs, which leads me to believe that it's caused by people leaving manual hubs locked in.

So my practice has been to leave them unlocked unless needed.

 

[Lerad92explorer]

Can a guy convert to the flat bearing washer like the Dana 28?

 

[Lerad92explorer]

Can a guy convert to the flat bearing washer like the Dana 28?

Or is there some after market fix?

 

[Shran]

Can a guy convert to the flat bearing washer like the Dana 28?

Maybe, you'd have to machine down the spindle a bit and find a suitable set of washers and a bearing. Or thinner washers and don't modify the spindle. I'm curious if a D28 bearing would work.

 

[alwaysFlOoReD]

Maybe go to a bearing supply place and get them to look for you. You would need to provide the measurements of the bearing you need.

 

[SenorNoob]

I'm pretty sure the D28 bearing is too small to go over the D35 shaft.

 

[Lerad92explorer]

I was thinking of just machining my spindle a bit shorter. Say a 16th or 1/8 of an inch off. Then there isn't as much pressure on the spacer.
It sucks living in an area with 5 months of snow or icy roads and have these hub issues.
I see now why my Dana 28s never had the locked in hub issue.
Thanks everyone.

 

[Shran]

I don't think simply shortening the spindle will help. The shaft can slide back and forth quite a bit... Probably just end up with the same problem. I would either try to figure out a bearing setup or unlock the hubs.

 

[4x4junkie]

I know I'm a bit late to the party here, but what worked for me was fully slathering those washers in bearing grease. I don't keep my hubs locked the entire winter (snow is almost unheard of here lol), but it is rare that I unlock them if I think I'll be using 4WD again within 20 miles or so after, say, exiting a trail onto pavement. If I had to guess, there's probably about 3K miles of hubs-locked driving on them.

Failing that, the later 3-piece washer setup used on '95-'97 Ranger D35 axles should fix it for sure. The 3-piece consists of an unsplined inner steel washer, a plastic (Delrin, I think) middle washer, and finally a splined outer washer. The Delrin piece acts as a slip surface so that the inner washer isn't spinning directly against the end of the spindle. Again, grease will be your friend.


Hope that helps.

 

[Shran]

the later 3-piece washer setup used on '95-'97 Ranger D35 axles should fix it for sure.

That's good information, I don't suppose you know offhand if you can still buy those parts from Ford?

 

[SenorNoob]

Ford is unlikely. But since it's a Dana axle...

 

[4x4junkie]

Yeah unfortunately I suspect this may be a junkyard-only item (I kindof doubt 25+ years after production ceased Dana would be a source either, especially with them having only had a three-year run). 1995-1997 Rangers and B4000s would be the ones to look for (the washers will be the same auto or manual hubs).


I wonder if one could fashion a 3-piece washer of their own if it came down to it... Two ways I think could work:
1, shorten the spindle slightly like mentioned above, then put a circle cut from a Delrin sheet or something between the existing spacer washer, and another (hardened) steel washer placed against the end of the spindle,
2, Machine (grind + sand, etc.) the existing washer thinner, then same thing with a circle made of Delrin and another hardened steel washer.

Just brainstorming some ideas.