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[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]HERE WE GO!
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]So getting right back into this, starting with the dang CV axle mix up
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Custom RCV axle does not fit the spider gear inside the dana 35 carrier
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I have a local machine shop that was going to try and help, I took a pair of axles down to them and the owner and I sat and talked about my options.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Turns out there is some super special tooling required to cut splines in axle shafts, they cut at like 5 different angles to get the splines in there. This shop is not setup for this, so they were un able to help (would require like tens to hundreds of thousands of dollars)
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]So I am going at this with a diamond tip grinder and a dremmel!
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]So far I am pleased with the results.... doing this by hand, very very carefully, only removing a little bit at a time
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]First up I needed a spider gear for proper fitment, so I took a IFS dana 35 diff apart to get one
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]remove cover
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]remove bearing main caps
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]remove carrier and bearings
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]To get the spider gears out must remove the roll pin with a drift and then center cross pin will come out
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]There we go, now I can use the spider gear to ensure the cv axle fits perfectly
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Prep the super expensive super "custom" (but not complete??) CV axles shaft
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]new diamond cutting wheels
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]So we can see the machine markings in the splines were left unfinished. There is a circular pattern cut in there, the final cuts were never completed by RCV.
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[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Here you can see I made several light passes with the dremmel to get the spline whipped into shape.
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]One down, 26 more to go, x 2 sides
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I spent a "few" hours on this, until my eyes were tired
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]After one pass:
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]The goal here is to remove the high parts and get the splined down smooth
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I did all the splines on both sides, now I am working to deepen the "valleys"
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]I fully expect the CV shaft to slide into the spider gear a little later this morning
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Tedious is the word of the day
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]About half way around the first side
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Hang in there folks..... this is gonna be a good one!!
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]As soon as I finish sorting out the suspension debacle I will be wiring up our drivetrain and Holley drivetrain computer MUAHAHAHAHAHA
[font="Segoe UI", "Helvetica Neue", Helvetica, Roboto, Oxygen, Ubuntu, Cantarell, "Fira Sans", "Droid Sans", sans-serif]Happy Spring! COVID SUCKS and all that...........nothing will stop me now
Last edited on Sun Aug 8th, 2021 05:52 pm by Eddie Money
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I know my crazy! Do you?
2007 Sport 4door 4x4 4.0L SOHC V6 Ranger