Build Badger the 40 series- front axle issue

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Overlandeffex

Overlandeffex

SILVER Star
Joined
Apr 30, 2016
Threads
199
Messages
1,866
Location
Escondido CA
Good morning everyone. I'm new to posting in the 40 series area but have extensive work with an 80 series. I'm currently in the middle of a body off restomod with my truck. Keeping stock axles...some what and up grading the driveline to a 4.8 LS motor to a turbo 350 and staying with a rebuild transfer case with adaptor. My first of many questions to come along is I am having a issues with the drivers side axle fitting in. I bought new axles from Cruiser Outfitter and put them in . Since I'm upgrading to a 2016 Tacoma disk brakes I went with 60 series knuckles and spindles. I ground out a bunch of the inside ears to fit the birfs like I have read in many of the post. The issue is when I put the spindle on and tighten it up it it seems like the axle maybe 5 mil too long and binds in the spindle. So I put it all together and now the axle will not turn. When the axles come....do you have to trim them some times??? Stock carrier parts in the diff and everything seems to mesh normally. Any help would be amazing. Taking everything apart now so will add pictures later.

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I have the backing plates installed.
 
When I replaced the Birfield axle shafts I had to also grind the inside of the knuckled balls to clear the Birfields. I put layout dye on the Birfields and then insert the shaft until it stopped the pull out and look at the contact. Then take to the inside with a die grinder until they Birfield slipped in and the splines engaged inside the differential then stopped.

Take you time and be patient and do a lot of cleaning.
 
Well.... I pulled it all apart and found it was hitting on the back side of the ball. Ground some out on both sides and now all good. Thanks for the community support. More to come
 
Well opening the thread up again.... NOT FIXED!!! So optimistic!!! So the only thing I can think of is in the third picture it shows the tip of the brif coming out all the way down in the spindle. My only thought after lots of in and out and grinding to assist the install is the ball is bent on the axle. What does the community think on that and how to fix? What additional info can I get to you smart than me people to figure this thing out??? Thank you in advance !!!!!
 
I think that is totally normal and the drive flange/hub will center it when installed with the hub.

Just a thought but I'm thinking the knuckles may not be centered properly shifting the birf into the ball. How did you determine what shims to install top and bottom? What happens if the knuckle studs/bolts are losened?
 
vfrer said:
I think that is totally normal and the drive flange/hub will center it when installed with the hub.

Just a thought but I'm thinking the knuckles may not be centered properly shifting the birf into the ball. How did you determine what shims to install top and bottom? What happens if the knuckle studs/bolts are losened?
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If I loosen the bolts every loosens up and the stem will turn. As shims I have just tried to keep the pressure need to keep the knuckle in spec. I have put no shims on the bottom and all on the top. No change.
 
Even with no shim packs in the bottom and all the shim packs up on the top it's still binding.
 
If I understand correctly you're not having a problem with the birfield interfering with the inside of the ball when installing it. You're having a problem with the spindle and birfield when the spindle is installed? The birfield doesn't want to spin. Have you installed the lockout to see if you can install snap ring? Sometimes I have to pull the birfield out to get the C clip on, which pulls the birf tighter against the spindle and away from the back of the ball. Also check and make sure the brass bushing in the spindle is fully seated.
 
pb4ugo said:
If I understand correctly you're not having a problem with the birfield interfering with the inside of the ball when installing it. You're having a problem with the spindle and birfield when the spindle is installed? The birfield doesn't want to spin. Have you installed the lockout to see if you can install snap ring? Sometimes I have to pull the birfield out to get the C clip on, which pulls the birf tighter against the spindle and away from the back of the ball. Also check and make sure the brass bushing in the spindle is fully seated.
Click to expand...
The issue is the spindle, when installed is pushing the birf down in it so locking up the axle from moving. After market axles and did the grinding that everyone says you need to do to get them in. Now I can get the spindle on without binding.
 
Did you use lay out dye to see where the Birfield was making contact inside the ball? That is how I knew where to use the die grinder. Are the knuckles aligned with the proper shims on top and on the bottom of the bearings?
 
Going to do the lay up again and had the proper shims.
 
I'm not familiar with aftermarket birfs, so you would know about grinding. I do know in the past sometimes I would screw a bolt in the end of the birf and pull it towards the spindle. Grease can push the birf towards the back of the ball. You might be fighting both areas.
 
Axles up to a certain year have smaller axle ball IDs than later years. and I did not know that when I ordered RCV axle shafts for the front until I went to install and they would not go in and engage the splines in the differential. I asked the question on MUD and was told about this and the inside of the ball needed to be clearance so that is what I did and kept checking with lay out dye so I did not take to much off. I did not know about doing the clearance until after I had set the alignment of the knuckles so I had to clean every time I finished grinding before using the layout dye.
 
The birfs from 76 to 78 FJ40 were the long birfs with the slightly smaller diameter birf. It sounds like the OP is having a problem with the birf contacting the back of the ball when the spindle is installed and not the ball opening.
 
I spilled my lay up fluid all over the floor. Damn it. Slipped out of my hand. Will have new fluid Sunday. More to come guys. Thanks again for all the help!!
 
pb4ugo said:
The birfs from 76 to 78 FJ40 were the long birfs with the slightly smaller diameter birf. It sounds like the OP is having a problem with the birf contacting the back of the ball when the spindle is installed and not the ball opening.
Click to expand...
My new birf are short and the HD hubs are for short birfs.
 
Overlandeffex said:
I spilled my lay up fluid all over the floor. Damn it. Slipped out of my hand. Will have new fluid Sunday. More to come guys. Thanks again for all the help!!
Click to expand...
I have done that a few times with varies fluids. I ended up buying the aerosol can.
 
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