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[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Spoke at length with Adem from True Travel
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]RCV is having Covid issues, axles have been back ordered since June!!
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]True Travel is aware of this issue and offered to send another axle BUT it might take MONTHS
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]So the other option is to clean up the splines ourselves to make it fit, which is what I will be doing (and others, we are not the only ones to experience this with RCV axles apparently)
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]This is a machining issue, the splines were cut deep enough but never "cleaned up" fully as far as I can tell.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]If we look closely at the RCV vs the stock shaft you can see the machine marks on the RCV splines, look like a round bit cutting a square edge.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I used a file to clean up the leading edge so it is more "rounded" like the factory piece, and to remove some rough bits that were left on the edge (would catch my fingernail) and now I have the shaft very very close to sliding into the diff, but I am not going to force it.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Today I plan to clean up the valley of the splines very carefully with a Dremel until the shaft slides into place.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I will get some pictures of the process, I need to pick up some dremel bits in town this AM then it is on.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I assured Adem I could handle these mods no problem, I am used to this kind of thing doing custom fabrication.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I see this as a small hurdle and will overcome.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]@JoleneTheExploder[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif] if you need you can send me your axle shaft and I can fix it up for you? Or follow along and get your dremel out! We can do this. I took EXTENSIVE measurements (like you) and found the CV shaft matches the factory part in every way, except the valley of the splines are just a tad too short (need deeper V)
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]COVID SUCKS
Last edited on Sun Aug 8th, 2021 05:51 pm by Eddie Money
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2007 Sport 4door 4x4 4.0L SOHC V6 Ranger