I guess I was lucky enough to get an uncommon d44 axle housing in my Jimmy. I need to install axle shafts and was wondering if I could just cut 1/2" off of a newer shaft? What problems would it cause if I cut it too short?
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.
Cutting axle shafts
- Thread starter LVJimmy
- Start date
If you cut that much how much spline would be left? That doesn't sound like alot, but it depends on how much you have left.
Stomis
Professional Amateur
What are you talking about "an uncommon axle housing"?
Its either a dodge, pass or drive wagoneer, bronco, chevy, or ford
Its either a dodge, pass or drive wagoneer, bronco, chevy, or ford
Splines are 2" long
What are you talking about "an uncommon axle housing"?
Its either a dodge, pass or drive wagoneer, bronco, chevy, or ford
That is what I thought. Until I tried to put new style axles in and they didn't fit. Looked up the BOM in the Dana book and found out the axle housing and shafts are different than the rest.
ALL D44 axles are the same length, sounds like you might be trying to install 10 bolt axles into a D44.
No, they ARE NOT all the same....
My BOM is 603170-8 or 9 (can't make it out) According to the Dana book it takes a 904686-1 and 904686-2. I have a set of shafts 29833-1X and 29833-2X but they are a little too long. The chart listed above doesn't show a 904686-1/2 but it does show a 904685-1/2, so maybe the Dana book has a typo?. If I use the dimensions of the 904685-1/2 it shows that the axle stubs are 0.33" shorter than the 29833-1X shafts that I have.
I think I could cut the shaft 0.33" without any problems however, I don't think I could cut the snap ring groove. So do I have a machine shop cut the shafts and the groove or do I just replace the housing?
Thanks for your help
What are the lengths of the shafts you have and the shafts you need? Measured from center of u-joint cap to end of shaft.
Stomis
Professional Amateur
To answer your question directly though yes you can trim splines but its no the best method and as said you're going to face other issues with snap ring grooves etc with stubs. However the end snap ring on a stud is really not necessary as the hubs have their own retaining ring. Lots of us run dana 44s and 10bolts with no outer snap ring.
This is the first time Ive ever heard of this problem and would be interested in seeing how it turns out for you. Im not super well versed in the dana 44 varieties other than the chevy axle but Ive always been under the impression there werent for example chevy axles with a 26in long short shaft and then a chevy axle with a 28in long short shaft from a different year. Perhaps your mismatched in the spindle or hub for the chevy outer?
This is the first time Ive ever heard of this problem and would be interested in seeing how it turns out for you. Im not super well versed in the dana 44 varieties other than the chevy axle but Ive always been under the impression there werent for example chevy axles with a 26in long short shaft and then a chevy axle with a 28in long short shaft from a different year. Perhaps your mismatched in the spindle or hub for the chevy outer?
If you look at the table posted earlier Chevy did use different length axles. Not sure why they would do such a thing but it does play havoc with the replacement. I'm going to switch out the housing and be done with the problem.
