35 spline full spool for stock 9 inch case

[JWMcCrary]

Maybe I'm the only one that wasn't aware of this but thought I would post it and possibly save someone else all the aggravation I went through today. I bought a full spool off eBay based on a recommendation here on this site, this was about 5 years ago. This spool will work with the stock case and uses the stock size bearings. I bought set of Yukon 35 spline axles. Fast forward to today, pulled the 3rd member out and swapped the full spool in for the 28 spline mini spool. No issues, everything worked out and setup fine. Pulled the inner seals out of the housing and stuck the drivers side axle in and bolted it up, all is well. Went to the passenger side and the axle will not go in all the way, lacks about an inch+, worried with it for a while but it's obvious it's bottoming out. I even started questioning having the short vs long mixed up knowing that I didn't. End result is stock length axle for the passenger side is 1.5 inches too long. They even tell you that if you bother to read information for the spool. The spool is splined all the way through so you start engaging splines at the bearing on the passenger side. So I've got to find somewhere to cut and spline this axle for me, which I've had 5 years to get done had I known.

Hopefully this might save somebody else the same issue.

http://www.ebay.com/itm/9-Inch-Ford...ash=item5b2feb274c:g:cEwAAOSwQTVV~gx~&vxp=mtr

 

[bronconut73]

I have seen guys cut axles within the extended spines with a cut-off wheel then chamfer the perimeter with a flapper disc.

 

[JWMcCrary]

I have seen guys cut axles within the extended spines with a cut-off wheel then chamfer the perimeter with a flapper disc.

That would work if I had splines farther down the axle, it's bottoming out at the end of the splines before it's all the way in. Needs to be cut off and splines 1.5 inches farther down.

 

[bronconut73]

That would work if I had splines farther down the axle, it's bottoming out at the end of the splines before it's all the way in. Needs to be cut off and splines 1.5 inches farther down.

A machine shop should be able to extend your splines as long as the axle diameter is maintained.

 

[JWMcCrary]

Yes, my son-in-law is taking it somewhere Monday to have it done

 

[ford man]

That would work if I had splines farther down the axle, it's bottoming out at the end of the splines before it's all the way in. Needs to be cut off and splines 1.5 inches farther down.

I did this several years ago I did not have to do that. I bought all my set up from Randy's ring and pinion.

 

[Yeller]

JW, rather than extend the spline just have a section turned down to minor diameter of the spline. It will work just fine, not hurt the strength of the axle and be much cheaper and easier to get accomplished.

It's a little different process but all of the high end shafts we have built the majority of the axle is turned down to minor diameter so we don't work harden and fracture the shaft at the spline and cause it to break as it gets stressed to the point of twisting.

 

[JWMcCrary]

So leave the length and turn down the area below the splines just enough to clear so that it slides all the way in ? I like that idea if I'm understanding correctly

 

[Skiddy]

interesting, I haven't heard that before. thanks for the heads up JW

 

[bigjhoov]

That recommendation might've come from me, since I run one of those spools. I recall having to send a shaft to moser to have a cut and spline done, but I think that was because the shafts that I used were from a wider housing. It's a minor thing to have done. Any of the major players should be able to take care of it. Moser, Dutchman, etc....

 

[Yeller]

So leave the length and turn down the area below the splines just enough to clear so that it slides all the way in ? I like that idea if I'm understanding correctly

Yes that is correct. Anyone with a lathe can get that done quick and easy. Then later if you decide to go to a locker you won't need a new axle

 

[JWMcCrary]

That recommendation might've come from me, since I run one of those spools. I recall having to send a shaft to moser to have a cut and spline done, but I think that was because the shafts that I used were from a wider housing. It's a minor thing to have done. Any of the major players should be able to take care of it. Moser, Dutchman, etc....

It may have but I was kicking myself not the recommendation Jerry. Sorry if that came across wrong. I think it work well when it's together.

 

[bigjhoov]

It may have but I was kicking myself not the recommendation Jerry. Sorry if that came across wrong. I think it work well when it's together.

I didn't take it that way. These things come up sometimes when you're working outside the box.

 

[Boss Hugg]

Or have the spool opened up and 1-1/2 deep?? but if it's already setup, that hinders it..

Myself probably would've stuck a 1-1/2 jobber bit in it and went to town... lol. Probably not the most correct way to machine a carrier bore.

 

[NYLES]

You might better get two!!!

 

[JWMcCrary]

Yes that is correct. Anyone with a lathe can get that done quick and easy. Then later if you decide to go to a locker you won't need a new axle

Thanks again, Jason called a guy that he knows that owns a machine shop and seems this is commonly done for the race crowd. We should be back in the saddle by the weekend and can move on to the next task. This thing may actually move under it's own power one of these days.

 

[Yeller]

Thanks again, Jason called a guy that he knows that owns a machine shop and seems this is commonly done for the race crowd. We should be back in the saddle by the weekend and can move on to the next task. This thing may actually move under it's own power one of these days.

Very good glad you found someone to help. The only one I know in that part of the world is Branic Machine in Ft Wayne

 

[5001craig]

Very good glad you found someone to help. The only one I know in that part of the world is Branic Machine in Ft Wayne

Branik is AWESOME! They are about a mile from where I work. Almost stopped in there today as I had my Bronco on a trailer and they setup my gears. They build some crazy tough parts and can do just about anything. They built an awesome 4 link front and rear for my buddy's EB.

Sorry for the hijack. Glad you found a guy. Back to spool discussion.

 

[JWMcCrary]

Thanks again for the suggestion Yeller, that was no doubt the best fix.
Slid right in.

So, for anybody searching in the future, if you are using a full spool, this one is 35 spline, that has splines all the way thru from bearing to bearing, you will need a 1.5 inch shorter axle or have the stock length turned down behind the splines to allow it to slide farther in. This is for the passenger side (long side), driver side is fine.

 

[Yeller]

And the reason it's splined all the way through is to add some section modulus to the bearing area, the splines add a bit of meat to increase strength do to the small bearing.