Shortened axle shaft doesn't fit in narrowed housing?

[Hagan]

So I narrowed my 78/79 Dana 44 axle 6". I took the cast wedge section off, cut the axle tube exactly 6" and I put the wedge section back on. I heated it in an oven to 500 degrees and slid it on then welded it together. I took my axle shaft (the long one) and had it cut and resplined. The problem is when I took it and put it into my housing it barely reaches inside the center section. So, for a reference I pushed both axle shafts (the stock driver side and shortened passenger side) and pushing them as far as they would go and the passenger side is much longer.

I can't figure out if I did something wrong? I honestly think they messed up. Can anyone help me out? The only reasonable explanation I have is I pounded the tube out of the center section. I noticed the plug welds were broken. Not sure if thats the case though.

Before

After

 

[Hagan]

Well, I figured out the stock length of the axle shaft. Its about 34" and I asked for it to be shortened 6". I received my axle shaft at 26". They chopped off 8"!!! Now hopefully they will do whats right and give me the right length shaft.

 

[legoms013]

Yeah the shaft should be 28" from end to center of u-joint. Hopefully they make it right (send you another stocker shortened, or a EB passenger shaft that takes a 7-560x).

Good luck.


Side note, how hard was it to get the cast wedgie off...I will be narrowing a 78 Hp D44 just like yours soon.

 

[Hagan]

Honestly it wasn't that hard. I actually was stupid and thought I could pound it off. I broke my hammer and bought a 3lb sledge and it came off. I might be buying another housing tomorrow....but I would HIGHLY suggest heating the wedge with a torch (funny because I have one!) that way you won't have to beat your life away and end up damaging the axle wedge. I damaged the square hole for the track bar. I thought I was going to weld a track bar mount on the axle when I could have used that mount for the track bar. Oh well lesson learned.