Mighty Mo and Friends

Home ] Up ] No Spark? ] 24 Volt from 12 Volt conversion system. ] [ D25 Cross Shaft Removal ] DANA 25 - Grenaded ] Dana 41-2 Axle Replacement ] Carter WO Rebuild ] OneWireAlternator ] Broken Exhaust Manifold Stud Repair ] ShackleReversal - Main ] Valve Keeper Installiation Tool ]

 

First the history:

I had the misfortune (ok I messed up) of breaking the drivers side front axle shaft in Mighty Mo. There were no spare D25-10 spline axles available and since there is a Lock-Right in there, I pulled the broken shaft out and wheeled the rest of the weekend in 3 wheel drive. When I got back home I repaired the body damage and then decided it was time to fix the axle. I have broken axles before and thought no big deal. I drained the differential, pulled the passenger side axle, removed the differential bearing caps and expected to be able to pop the carrier right out. WRONG.

I worked on this for off and on for  a week and a half. The factory manual says that a housing spreader should be used and not to exceed 0.020" spread. My home made spreader could not get more than 0.010". I had previously used this when I installed the Lock-Right so I was confused. I noticed that the housing spreader was bending. Eventually I built a housing spreader out of 1/2 x 2" steel. The original was 1/4 x 1 1/2" steel. This provided 0.020: spread but even using a 3 foot crowbar, the carrier refused to come out.

I was talking to Bob Stevenot  (Stev) and he suggested I might be able to remove the broken piece on the side gear if I remover the cross shaft and used something to drive it out. This proved to be a "forest & trees / alligators / swamp" moment. Thank you Stev.

When I attempted to pull the cross shaft I found the shaft would not slide out past the ring gear. I had read that some people have slightly ground the teeth of the ring gear to remove the cross shaft with out any problems to durability of the ring gear. A few minutes with an air grinder and the pin slid right out. See the pictures below for the entire process. If the ring gear fails, or there are other "issues" I will revise this page with a warning. Since the gear required very minor alteration, I don't expect there to be any problems though.


OK so here is the bronen alxe.

The cross shaft is held in by a pin. I used a screw driver and a punch to start the pin moving.

Then vise grips on the punch gave me something to tap on.

And out comes the retaining pin.

This is the carbide "wheel" I used It is just larger than the shaft dia

Just a small amount of metal is removed.

Looks like the shaft will clear

And out it slides.

Like I said before, I have read that this is a safe modification. I decided that I would try it. Do this at your own risk.

 

 

 

Back to top of page

Back to Main page

Visitors since November 23, 2006

Hit Counter

Copyright Richard N. Meagley Sr.
Last revised: May 25, 2007.