diff..axle problem

[61shorty]

just took the 3.91 geared 741 case out of my 61 (63 axle).....installed the 3.55 geared 741 case and all was going great until i got the driver side axle slid in and it bottoms out with 1/4" to go !!! both diffs open, non posi units..the pass side went in no problem..i've swapped a ton of these around and never had this problem....do i whip out the chop saw and whack a 1/4" off the axle ???.....help.

[712edf]

Would it matter if you reversed the order of axleshaft installation? Theoretically it shouldn't matter, but seems like the planets must be aligned sometimes for these things to go back together properly.

Bucky

[Jones]

I think this is what your coming up against. This is some what lengthy, but it explains what's going on with your axles.

http://bionicdodge.com/Download/Mopar_8 ... _Guide.PDF

Keith

[61shorty]

thanks for the replies............i did'nt swap the axles side to side.........and the axles in those diagrams are way different in length, i'm only off by just under 1/4 inch.....both 3rd's came out of the same year trucks, both 741 cases...and the pass side fit perfect...can i carefully cut the 1/4 inch off and make it work ??

[j2007]

Are you sure you are bottoming out, or it maybe hung up? As weird as this sound you can buy bearings with the same part
number on, and be off by a couple of thousanths (bad quality control). Is it possible it is becoming an interference fit?

[61shorty]

it was hitting bottom for sure....i was also using the same bearings....well today i got out the chop saw and fixed my problem. whacked 1/4" off the end and beveled it, and cleaned up the splines. worked out perfect. took it on a little road trip and all is well. thanks for all the replies.

[truckluvr]

Well sounds like I'm answering this a little late but, yes when I've narrowed rear ends for racing I would usually have to "custom fit" the axles. of course I used a porta-band saw but same theory.