Technical Is my axle shaft too long?

BINGO!

I used an old shower curtain rod & measured a bit over 25".

Then measured the axle; almost 25 1/2".

Time to cut the axle.
Thanks again, guys, for all your help.

 

Be sure to check the spline length and make sure the axle shaft doesn't stop short after cutting.

 

This makes quick work of it:

https://dutchmanaxles.com/measuring-tool-ford-9.html

Guess link doesn't work:

 

Hello, the distance is 1 1/8 inches - in a STOCK OEM configuration
the cross shaft in the diff is 3/4''

the 5mm of air each side is because........
the PITCH of the crown wheels of different gears alter the final position of the carrier when setting the back splash so there has to be some space.
ergo - you are still pissing in the wind as the shafts you have at 1'' of space WOULD work fine as they would clear the 19.050 3/4'' cross shaft with a 1/16 of an inch on each side
BUT ONLY
with the crown wheel pitch of whatever the original gears were, as you could change the gear from what came out of it and it touch.... I.E. who ever done builded that axle purposely but 1/16 of an inch clearance when cutting the axles the first time with the gears in the centre section.......

 

So....
I followed @19Eddy30 's advice, trimming about 1/4" with my trusty 4.5" Dewalt grinder and a fresh cutting wheel.


Then beveled the edge with a grinding wheel and filed each splines' inner diameter.


Everything test-fit nicely, so I reassembled the whole shebang.


All done!
Thanks again for all the guidance.

 

Nice Gary. It will work just fine. Problem solved!

 

Glad you got it sorted.

Regarding "shortening shafts" ... the pics of the power tools and a finger with a ring on it did make me cringe

"Giving the finger" is a motoring gesture term ... it should not be used medically

 

Winner winner chikin dinnyr