Do I need new axles or is it something else?

[BHowTJ]

Do I need new axles or not?
I had a blown seal and loose bearing so I’m replacing. Replacing with these repair bearing which I’ve never used before so I don’t know much about them. I installed the new bearing but the axle WILL NOT go in the tube far enough to spline with the spiders. It seems to be catching right where the old bearing road on the axle. there is some wear on the axle but I didn’t think it was excessive, maybe it is. I can persuade it with a mallet, but I don’t want a booger up the splines on the spider gear or the axle. I’m just curious is the wear on this axle too excessive to reuse or perhaps there’s something wrong with the repair bearing.

 

[macleanflood]

New axles would be the most sanitary solution, yes.

You could build up the missing material and use a lathe to turn it down to the correct width...but they you're compromising metallurgy and temper.

-Mac

 

[Woodrow]

What axle do you have; Dana 35 or Dana 44? Are those stock or CroMo shafts? If those are after market CroMo shafts in a Dana 35, this is an example of that alloy not having the surface hardness necessary for direct contact with the rollers in a Dana 35. If its a Dana 44, then the pressed on races have spun perhaps? In either case, you need new shafts. Either stock or alloy (1541H for Dana 35/ CroMo for Dana 44).

 

[CMBD]

Do I need new axles or not?
I had a blown seal and loose bearing so I’m replacing. Replacing with these repair bearing which I’ve never used before so I don’t know much about them. I installed the new bearing but the axle WILL NOT go in the tube far enough to spline with the spiders. It seems to be catching right where the old bearing road on the axle. there is some wear on the axle but I didn’t think it was excessive, maybe it is. I can persuade it with a mallet, but I don’t want a booger up the splines on the spider gear or the axle. I’m just curious is the wear on this axle too excessive to reuse or perhaps there’s something wrong with the repair bearing.

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That is excessive wear.

Would guess .030"+ difference between the two surfaces.

No idea what the spec is, but I would have to believe that is way out.

 

[JMT]

Do I need new axles or not?
I had a blown seal and loose bearing so I’m replacing. Replacing with these repair bearing which I’ve never used before so I don’t know much about them. I installed the new bearing but the axle WILL NOT go in the tube far enough to spline with the spiders. It seems to be catching right where the old bearing road on the axle. there is some wear on the axle but I didn’t think it was excessive, maybe it is. I can persuade it with a mallet, but I don’t want a booger up the splines on the spider gear or the axle. I’m just curious is the wear on this axle too excessive to reuse or perhaps there’s something wrong with the repair bearing.

View attachment 647512

View attachment 647513

The bearings ride on the Dana 35. You don’t want a 4340 shaft like for a Dana 44, but a 1541H.