Fitment issues with rear disc rotor

[fordguy]

I have stock axles with Currie drilled explorer rotors. I had to turn the boss on the axle, now the bosses on the wheel studs are keeping the rotor from seating flush. See pics. I did not want to drill the rotors just yet. Wondering if the aftermarket axles are different. Will contact vendor Monday. Just picked the axles up late yesterday. Rotor is on backwards to show gap size.

 

[399strokerEB]

Interesting, I have this kit on my mustang and ordered it for my bronco. I'll check mine when it shows up. How big are the holes?

 

[fordguy]

Have not measured but it is the size of the threaded part of stud. The boss is bigger

 

[DEEPWOODS]

Every one I have done the outside edge had to be turned down on the the axle to fit in the rotor hat flat

 

[Apogee]

If the rotor is hub-centric on the axle rotor register, than it doesn't matter how big you oversize the wheel stud holes in the rotor...just make them large enough to clear the shoulders on the wheel studs and call it a day.

If the rotor is not hub-centric, then size the wheel stud clearance holes in the rotor for the shoulder diameter of the wheel studs, and let them locate the rotor.

If you need to machine down the axle flange diameter for the rotor to properly seat fully, then reduce that diameter accordingly and/or add a chamfer to achieve the desired result. As long as you have at least 1/8" of material outside of the wheel stud knurl diameter, you should be fine.

In a properly setup rear disc brake kit, the wheel studs should be in pure tension and won't see any shear loads due to the brake forces, as the rotor is sandwiched between the wheel and axle such that the only way that could happen would be if you didn't adequately tighten/torque the lug nuts.

Tobin

 

[fordguy]

I have already turned the axle hub, and we can enlarge the holes, just curious why they are already not enlarged unless the aftermarket axles are different. If they are I can wait, these axles are temporary. I will let y’all know what Currie says.

 

[bronconut73]

The aftermarket axle flange might be thicker. That would probably not allow the shoulder of the knurled edge to poke through. For example I have heard that Dutchman axles haves a very thick axle flange compared to OEM and even some aftermarket axles. So there are variables. I think you're right about the aftermarket axle having a thicker flange and you might not have to worry about that edge of the studs sticking up

 

[fordguy]

Think you are right on flange thickness

 

[399strokerEB]

I got half my kit tonight, the stud holes are almost 9/16". I'll try and put a rotor on tomorrow, not sure if it will help you or not as I have aftermarket axles and wheel studs. Which kit number did you get?

 

[fordguy]

My kit is straight off an explorer with Currie drilled rotors

 

[399strokerEB]

I wonder if you got 7/16 drilled rotors, j would measure them.

 

[Broncobowsher]

Different mix of flange and studs. I've had to go stud shopping for unicorns. The front stud matched the specs on a bone stock rear axle on an F250. Now add in you are mixing parts that were never intended to fit, but modifications were made.

Have the rotor properly indexed on the axle, put a chamfer bit to the back side of the rotor and run it in deep enough everything will clear. Done.

 

[fordguy]

Measures 9/16th, will call Currie before I do anything to the rotor, suspect it will fit their axles fine