axle shaft is broken - Dana 60, 4.88 gear

MowagW200 · Post by **MowagW200** » Sat Feb 04, 2006 7:00 am

After firing up the engine with the new parts in it and break in of the camshaft my friend went up for a test drive.

Unfortunately he was driving the truck just 1/8 of a mile. Then he heard a bang and the truck didn't move forward anymore. The result is that the right axle shaft is broken just where the splines end. It's the second time the same shaft is broken

. So I wonder what's the cause. Is it a misalingement of the diff or the wheel bearing stub axle.

What can I do to prevent further axle shaft ruptures?

dodgetkboy78 · Post by **dodgetkboy78** » Sat Feb 04, 2006 6:53 pm

Gee..................
If it was that bent, it would be a pain to get in and out.

Same side?

Jims68 · Post by **Jims68** » Sat Feb 04, 2006 7:31 pm

I think I still have BOTH axles out of the Dana/Spicer rear from my D-200 when I junked it. Let me know if your interested, and I can email you some pictures of them.

Jim

dodgetkboy78 · Post by **dodgetkboy78** » Sat Feb 04, 2006 8:09 pm

Count the splines, the carrier on the 4:88's used a real coarse spline, if I remember right.

dodgetkboy78 · Post by **dodgetkboy78** » Sat Feb 04, 2006 8:09 pm

Count the splines, the carrier on the 4:88's used a real coarse spline, if I remember right.

MowagW200 · Post by **MowagW200** » Sun Feb 05, 2006 6:40 am

Thanks a lot for all your reposts. As far as I concern the original shaft from the drivers side has 16 splines. Actually the shaft from the other side has no one, because the part with the splines is still sitting in the carrier.
Jim I'm interrested in one of your shafts as long is it has 12 splines, too. Do you have the cones sitting round the bolts of the hub, too? During mounting of the shaft (when I mounted new bearings on the hub) I didn't recognise any bigger resistance than on the drivers side. The broken shaft does not have funnel-through cones. I think, the cones are used to center the flange.
If the axle is bent, then I think it would make sense to exchange the hole axle with both wheel bearing stubs.
I would appreciate any hint very much. Thank you all folks.

Jims68 · Post by **Jims68** » Sun Feb 05, 2006 7:42 am

I will check the splines, and get back later today. I think I have some of the cones too. I will also check on that.

Jim

Jims68 · Post by **Jims68** » Sun Feb 05, 2006 9:23 pm

I just counted the splines, and these are not the axles you need. Sorry. 12 splines must make for BIG splines! Mine were somewhere around 30 splines. I do have quite a few of the cones from the axle bolts if those are the same as yours. Let me know, and I can email you picts, measurements of the cones, etc.

Jim

MowagW200 · Post by **MowagW200** » Mon Feb 06, 2006 8:17 am

About the splines count. I got out, that all new spider cages and axle shafts for a Dana 60 rear axle have 30, 32/33 (depending on manufacturer) or 35 splines. It seems like the coarse spline axles shafts like mine have an engineering fault and were produced for only a short time.

dodgetkboy78 · Post by **dodgetkboy78** » Mon Feb 06, 2006 1:14 pm

I think the low geared trucks (4.88+) got them from like 63-4, to 68?
Just from what I have seen, I have no documentation to back me up.

MowagW200 · Post by **MowagW200** » Tue Feb 14, 2006 1:25 pm

Jims68, look the cones have the following size:
outer diameter: 3/4" (the bigger)
outer diameter: 0.5" (the smaller)
inner diameter: 7/16"
hight: 13/32"
the cone is sliced.
If you'll find 8 of these cones I would be very happy, thanks.

Jims68 · Post by **Jims68** » Wed Feb 15, 2006 7:33 am

I will measure mine today; and let you know the size.

Jim

Jims68 · Post by **Jims68** » Wed Feb 15, 2006 3:07 pm

Mowag, Look for an email from me. Yes, I have what you need.

Jim