Tom's Bronco front disc conversion... Help

[wegngis]

Here's a quick video that attempts to further demonstrate the issue.

http://youtu.be/tlAMB93d3SE

 

[Teal68]

Weg,
Once you posted the pic it's obvious the new spindle is shallower. The video is even better. That said I have to wonder if it's even a problem since the instructions say that the clip may no longer go onto the end of the shaft. For that reason doesn't the kit come with a bolt, star nut and washer to go in the end of the axle? I just did the WH kit, and while I did not have the problem you are, it does clearly state that what is happening to you is very common. I'm very curious whether it's a problem or not, and what the vendor has to say.
Keep us posted,
Tyler

 

[savage]

I read the instructions for Toms and they say not to use the c-clip. 4. Install Locking Hubs: As a reminder, you MUST use aftermarket locking hubs with this conversion kit. Referring to the manufacturer instructions for your locking hubs, install them into the
hub assembly. NOTE: The SMALL snap ring that mounts to the end of the axle shaft is NOT used for installation. DISREGARD the SMALL snap ring that normally mounts on the end of
the axle shaft.

 

[DirtDonk]

The clip is never really an issue as even changing out to Warn hubs on an otherwise stock Bronco front end will almost always exclude the use of the clip. However, if his axle shaft is truly jammed up tight when the spindle is installed, then I consider that to be a problem.

I could be wrong on that of course, but every axle I've ever worked on had that play from the factory, so it should convert to his Dana 30 as well I would think.
If not, the back of the spindle, the seal and the slinger would wipe each other out pretty handily when in 4wd I would think.

 

[savage]

I agree DirtDonk, when you tighten the spindle bolts their still should be a little play or movement. Mine was not a Dana 30 but a Dana 44 that I put the same kit on, and still had some in and out movement. DirtDonk do you think having the slinger on their is making it tight? In the instructions it says,NOTE for Dana 30 Installation:
For Dana 30 Installation, you will need a Dana 30 Spindle Seal which will be
used IN PLACE OF the Spindle Bellow Seal. Install the Bearing Seal, Thrust
Washer and Spindle Seal into the back of the spindle (See Figure 17 & 18). This
will require you to check if your outer stub axles have slingers or not so that you
can order the correct spindle seals (Figure 15 & 16)

 

[DirtDonk]

I would have said that was worth checking on, but wegngis has said that the seals are the same, and that the wider surface of the axle stub (where the slinger goes) would fit into it if the axle shaft shoulder wasn't bottoming out first. So unless the slinger was sticking out proud of that surface, I don't believe that removing it would have an effect.

Now if it was the seal that was being hit by the axle instead of the spindle, then even that little bit of glorified sheet metal might be enough to make the difference. But in this case, it doesn't look like it.

What I've always found strange is that the bellows seal won't work. Since it actually fits around that wider slinger surface and compresses very easily for part of it's thickness, it seems like it should not interfere with any function.
But if they say to not use it even without the spindle seal, they've obviously run into something before.

Paul

 

[wegngis]

When I get home I will go over everything in the documentation. Maybe I missed something in regards to not being able to put the clip on.

 

[savage]

The instructions I was looking at was on Toms site, and it was number 4 on the instructions sheet.http://www.tomsbroncoparts.com/page...in/dana-30-and-dana-44-disc-brake-conversion/

 

[Teal68]

Weg,
In post number 16 by Savage, you didn't install the washer in the lower right of the pic he posted between the bearing and seal did you? If so, that is what is holding it off some. Just throwing something else out there to think about.
Tyler

 

[wegngis]

Yes, the instructions do say I will not be able to install the outer clip. I also called Tom's and they confirmed that the new spindle will not seat fully against the slinger in a Dana 30. As long as it's engaging enough and that seal is sealing stuff out, that's the goal and it should be fine. So, after a long weekend of figuring this out, it's time to dive back in.

I did install that other washer, (can't remember the name at the moment) but apparently that's all ok.

 

[DirtDonk]

The plastic (or bronze in some cases) washer with the beveled inner edge is a thrust washer to keep metal turning bits from contacting metal stationary bits. Very nice to have, assuming it will work with yours.

Paul

 

[wegngis]

Yes, the thrust washer. That is indeed installed. It adds just a tiny bit of thickness. Seems like it would be chewed up, being between moving and stationary metal, but that's what it calls for.

 

[hankjr]

So in a similar vein, what do your studs look like? I was just going to press mine in and they look wrong. They look like they will sit too far out.

View attachment 345403

View attachment 345404

View attachment 345405

Thanks.

Hank

 

[DirtDonk]

Don't forget the rotor thickness. They're pressed through the rotor too, and retain it to the hub.

Paul

 

[wegngis]

You're talking about the lug nuts, right? They're fully seated, but they came that way. This is the best picture I've got on my device at the moment, I can take one more like the angle you're showing later tonight.

Or maybe you're talking about the bolts that secure the spindle and backing plate to the knuckle?

 

[savage]

X-2 plus rotor thickness,their work . That's what hold the rotor to the hub. Once you guys get it done its worth all the hassle!!!!

 

[hankjr]

Rotor thickness. Right right right right.....

 

[hankjr]

My homer moment of the day....

 

[Teal68]

Yes, the thrust washer. That is indeed installed. It adds just a tiny bit of thickness. Seems like it would be chewed up, being between moving and stationary metal, but that's what it calls for.

Weg,
The conversion I did was also on a dana 30. Since it did not have the thrust washer I did not use one in the conversion. I think the thickness of that washer is your problem if you want it to seat further. Sounds like there is no harm in leaving it though. I just had enough room to put the c-clip on. No room to spare.

 

[Pa PITT]

... I'll add my 2cent worth .. In post no 16 by Savage those 2 rubber seals the fiber or bronze spacer and the needle bearing that goes inside the spindle .. That BCA PART NO. is SBK1.... NORMALLY WHEN YOU GET THE SBK 1. YOU DON'T RECIEVE THE spacer but if you get the same part no from NAPA THEN YOU DO GET THE SPACER.
... On the several swaps I've done ..But with junk yard parts.. Not TOMS ... I'VE been able to put a pry bar in behind & move all mine in & out about 1/8 too more inch on them... Hench making it possible to add the C Clip ...