Technical No Woo Hoo Moment, 9” Axle Splines

For the first time I got myself up close to the rear end under the 32 project then this happened…
While looking in the housing (no 3rd member installed yet, just axle’s) I seen how large the axle’s really are, 35 spline! All this time I thought this thing was only to be a cruiser. So why would have Carina purchased large axle’s years ago. That hunch led me to purchase a 31 spline 3rd member some time ago.

Question is, can these axle’s be machined down enough (just where they insert 3rd member) that the 35’s disappear totally so 31 splines then can be machined onto them?

Ok, I’m behind the chicken wire now. Let’s have it.

 

will a caliper show that-?--we can worry about hardness later...

 

If the net would supply me with people answers on axle diameters vs AI take over I’d be more able to answer that question.

Just kicking ideas around. Probably cheaper to get replacement axle’s vs machine work and treating.

 

Sell the 35 spline axles (usually race stuff) to someone that can use them and buy 31 spline axles to go with the carrier that you already have.

 

The minor diameter of a 35-spline axle is 1.4167".

The major diameter of a 31-spline axle is 1.2500".

So, yes.

 

And if you have them machined make sure there is a "healthy" radius at the end of the cut.

 

buy a 35 spline spool and be done with it

 

Having done some axle re-splining back in the day, I'd have to suggest either finding a 35 spline diff (near impossible), or sell the 35s and buy 31s as jmountainjr suggested.
I was never able to recut splines without annealing the steel first. High speed steel tooling wont cut it, carbide breaks. Then, if you don't get the heat treating just right after machining, the axles could either twist or snap.
And for what it would cost to do that....just might exceed the cost of new axles.

 

This: https://www.strangeengineering.net/...ifferentials-spools/ford-9-inch-differential/

Plus a case bore, or a large bore case.

 

If you go shopping for 35 spline stuff you need to know the pressure angle of your axles.

 

Maybe a call to Moser Engineering would answer the axle spline/re-splining questions?

Lynn

 

Moser Engineering is great to deal with and will make custom shafts for you. You’d probably be better off selling the 35 spline shafts and buying a replacement set of 31 splines.

 

a friend of mine had a Dana 60 with 9 inch bearing ends that used 35 spline axles, just another option

 

35 spline is really common on a Dana 60

 

https://www.currieenterprises.com/c...MQz6Gxc9UHtxr0fxvDr5mZ9GAHKHc8m2oNBpNCV3OD4th

 

Need 5 on 5 1/2”

 

31 spline 5x5 1/2 $300 pair https://www.quickperformance.com/Qu...-Custom-Alloy-Axle-Shafts-1-Pair_p_22575.html

 

Looked them up all ready.

 

I have no idea of their quality but the cut to length 31 spline Big Bearing axles Speedway sells aren't that expensive. $226.00 Pr. Probably cheaper than having s local shop set up to cut yours? Plus the new axles come with new bearings.

 

Going from memory here, but I seem to recall that 33 spline is the largest that will fit a stock carrier. So even if you did cut down 35 spline to 31 spline, the modified axles won't work as they won't fit through the bearing.

 

Sure they will. Just have to machine them down further toward the wheel flange.

 

True.Not all brands will interchange, even though the spline count is the same.

Another vote for Q/P axles. Good people.

 

Redbird Speed sell’s Quick Performance as well.

 

Correction on 31 spline diameter OD is 1.330 +/-, 28 are 1.250 dia. DO NOT mess with the 35 spline axles. NOTHING BUT TROUBLE. The chance of success is minimal, cost will be staggering.

 

sell the 35 spline axles to a rock crawler and get you a set of 31 spline

 

Reply #5 from @gimpyshotrods is the answer I was after. This does not mean I’m going the route of having axle turned down and resplined. Just that my question has been answered. In the mean time I have a few welds to get done (red arrows). Wrap up brake pedal switch. Fab up battery box/tray then paint mid section of the frame so cab can be dropped back into place. When that’s complete the bed will be removed. That’s when I’ll finally know what I’m going to do about my mistake.

 

what brand are the axles what length are they?

 

No idea. Project all ready had them before I got involved.

 

@big john d mean anything to you?

 

If Cook’s is still around, I’d give them a call. There isn’t much they haven’t done in the way of rear ends and axles and they are out your way unless they moved.