We are for sure going to cut down our dana 60's. And was wondering how they re-spline the axle shaft when they shorten it? Because of how the axle shaft is made at the splines that goes into the case there is HUGE then it taper's down into a smaller shaft? do they cut the big end off then cut what they haft to off the shaft and re-weld the big end with the splines back on? Does it make the shaft weaker when they re-spline it?:confused: :confused:

you could use a grinder and do it :flipoff2: :flipoff2: just joking, how about you just send them off to Moser, or Currie it not that ewspensive for all you cheap bastards out therel.:rasta:

you can only shorten a shaft if the diameter where the new spline will be is larger o.d. than the depth of where the spline are now. I am assuming that this is an older ford front or rear 35 spline :smokin:

On a rear 60 axle or a 78/79 front 60 axle you won't be able to respline them. If you were doing a 9" then it is easy because the splined area is the smallest part so they are easy to grind down the the right size and then cut or grind new splines.

cut or grind? you suuuuuure about that? i thought the were forged more that cut. the press that is used uses multiple passes to form new splines and arrange the grains to increase strenght. i really don't think a grinder is the way.

i'm sure somebody will be on here soon to set us straight.

-russel

Thanks CJ_Dean I have the 78/79 Dana 60 front that I am putting under my CJ-5. And then the 60 rear out of the same truck. What did you do for your shafts? Our did you leave them full width CJ_Dean?

Yes grind. If you get some axles from the factory they have rolled splines then the axle is heat treated but since we are talking about resplining the 2 most comming ways are to cut the axle down on a lathe and then cut the splines on a milling machine with a dividing head and tailstock. The other is the way Dutchman does it and that is with a CNC diamond grinder and if you see their product you won't want it done any other way. Much more precise and less stress on the axle. Rolled splines are the way to go if you can get them but I only know of stock replacement lengths offered this way.

another method is to broach splines, but i dont know of anyone thats doing that right now.
almost all front axleshafts can be cut down, but most rears can not.
i thought moser rolled splines.... perhaps not..

Originally posted by elusiv
another method is to broach splines, but i dont know of anyone thats doing that right now.
almost all front axleshafts can be cut down, but most rears can not.
i thought moser rolled splines.... perhaps not..

They usually don't use a broach to spline the outside of a shaft. They are usually rolled or cut. When rolling is used they often harden it by way of an induction coil. This makes the crystal structure the same throughout the the shaft. Then sometimes tempered. Its about what characteristics you want form the shaft. Go look at an iron carbon phase diagram if you want to learn more.

I'm pretty much up on the metallergy of annealing, hardenening, tempering, crystaline structure and such ... but can someone give the defination (process) of "rolling"?
Sounds like the end is cherried hot and a roller is run on the ends to make new splines .... ???

Originally posted by Alaskan Assassin
Thanks CJ_Dean I have the 78/79 Dana 60 front that I am putting under my CJ-5. And then the 60 rear out of the same truck. What did you do for your shafts? Our did you leave them full width CJ_Dean?

Ya need to come down and talk to Curtis and I at the shop, and we will get you hooked up.

By the way, that was some pretty good breakage Sunday. And how much does that thing weigh? You were sure dragging my junk all over the place. To bad it was dark, would have made for some impressive pics.


Dan

Originally posted by Alaskan Assassin
Thanks CJ_Dean I have the 78/79 Dana 60 front that I am putting under my CJ-5. And then the 60 rear out of the same truck. What did you do for your shafts? Our did you leave them full width CJ_Dean?
With the 78/79 Ford 60 you are stuck with full width or buying new axles because they have the taper to them where the newer 60s are bigger so you can cut them down. On my 60 they front uses a stock short side Ford and the long is cut down. On the rear I used 14 bolt outers and upgraded to 35 spline. The stock axles can not be resplined unless it is to something smaller than the axle. I went with 60" wide becaue you need to run about 2.5" or so backspacing if you run 15" wheels so that will make it quite wide if you go full width. I have 2" backspacing 15X10 wheels with 39.5X15X15 TSL's and my overall width is 83.75. Here is a shot to give you an ideahttp://www.respite.org/images/cj66dean/myjeep2.jpg

Originally posted by Jaffer
I'm pretty much up on the metallergy of annealing, hardenening, tempering, crystaline structure and such ... but can someone give the defination (process) of "rolling"?
Sounds like the end is cherried hot and a roller is run on the ends to make new splines .... ???
they don't have to heat it, just roll it, then harden it after.

If you go to the web site for Foot Forge and Axle, I thinkthe makers of Superior Axles and Gears, among other things, they explain that they heat treat first, then machine. They explain that the heat treating will cause warpage, so they first heat treat it, then machine the surfaces. I'd imagine the splines can only be rolled at high temperature, so that a procedure for original manufacturers only, after that it's purely machining work to cut down and respline. That's also why it's better to custom order a new axle from Currie, which is then fully heat treated and rolledsplines, than to have them cut your old ones down and machine new splines.

Tim

This is an argument that they the manufatures still argue about. What is the best way? Just because they may come from the factory one way is rarely a good way to judge because they really only care about cost.

Originally posted by elusiv
another method is to broach splines, but i dont know of anyone thats doing that right now.
almost all front axleshafts can be cut down, but most rears can not.
i thought moser rolled splines.... perhaps not..

Moser cuts 'em, not rolls 'em. They cut down my 9" axles. Great prices and great service.
www.moserengineering,com