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Old 02-26-2002, 11:19 AM   #1 (permalink)
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Help with 9" FF flanges

I've been asked to machine up some axle flanges to make a 9" FF using D44 front spindles. My main question is where to put an O-ring groove on the machined flange so that it seals. Looking at the spindle it looks like the best place is on the flat surface just to the inside of the locating lip or at the bottom of the groove for the locating lip of the spindle on the machined flange.

Your input is appeciated.

JP
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Old 02-26-2002, 11:24 AM   #2 (permalink)
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personally i'd rather see the seal in the adapter piece that you're making to bolt the D44 spindle to the 9" housing ends. that way if something ever happened to the spindle getting a replacement is not another custom deal. but that said the places that make FF kit's for toyota rear axles put the seal in the spindle. so, what do i know ...

- jack
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Old 02-26-2002, 11:26 AM   #3 (permalink)
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The locations that I was referring to will both be on the machined axle flange; not on the splindle it's self.

JP
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Old 02-26-2002, 11:32 AM   #4 (permalink)
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oh ... i misunderstood what you said.
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Old 02-26-2002, 12:01 PM   #5 (permalink)
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I did up a quick drawing if someone wants to post the jpeg for me.

JP
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Old 02-26-2002, 12:53 PM   #6 (permalink)
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Old 02-26-2002, 02:54 PM   #7 (permalink)
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Old 02-26-2002, 05:12 PM   #8 (permalink)
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From the picture you can see that one possible o-ring location is at the bottom of the locating groove that the spindle lip fits into, the other is the flat surface just inside of the groove. I don't want to try to seal on a surface of the spindle that is machined from the factory for clearance because the tolerances would be pretty loose.

JP
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Old 02-26-2002, 08:18 PM   #9 (permalink)
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i don't think that we need an o ring in there as ATV silicone would do the same job. the one thing we do need to figure out is how to seal the axle. would it be okey to make the inside diameter of the flange the right size for a seal to be tapped in. this way no gear oil will be lost. another idea is to make a aluminum puck that has to be tapped into the back part of the spindle (around 4" diameter) and have a hole in the middle that will except a seal to seal the axle. hmmmm.
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Old 02-27-2002, 10:29 AM   #10 (permalink)
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i'm with cornjeeper, sealant will be fine between the adapter and spindle since they're both machined surfaces. my concern is the seal around the axle shaft to keep the fluid in.

- jack
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Last edited by morpheus; 02-27-2002 at 10:31 AM.
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Old 02-27-2002, 10:55 AM   #11 (permalink)
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The flanges are for cornjeeper and someone else. It'll be easy to put a groove in rather then have it leak because the RTV got pushed out of the mating parts -- this is not like a diff cover where you can have a .025" gap to fill with goop. With sealing the axle the problem that I can see is that you'll need a machined surface on the shaft for the seal to sit on; but the sealing surface on the shaft would have to be a large diametre then the splines so you don't damage the seal when pushing the shaft through. Another option would be to have the outer bearings running in grease and have the shaft seal on the inner bearings; but the shaft diametre is still a problem.

How do the Warn kits seal? Is there a way to seal the hub assembly?

JP
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Old 02-27-2002, 11:09 AM   #12 (permalink)
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well if i am right the 31 spline end of the axle will not fit through the spindle so to assemble it the axle needs to be in then the spindle goes on. the shafts that we are getting from moser will have a machined surface and they will be able to tell us the diameter of the surface. then all we need to do is go to lordco and find a seal that will work with the shaft. after we pick out the seal then a recess needs to be machined in the flange to accept the seal. it is as simple as that.

now to butt weld or press fit????
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Old 02-27-2002, 11:31 AM   #13 (permalink)
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Quote:
Originally posted by strong_like_tractor
How do the Warn kits seal? Is there a way to seal the hub assembly?

JP
the warn's are setup to run likee a conventional FF axle, with oil bath hubs, or you can install an optional seal that rides on the axleshaft and seals the hubs from the axle housing. This seal is notorious for leaking though, as most housings aren't perfectly true, and as a result you get a shaft wobble, and it eats the seal in short order, so you still wind up with oil in the hubs, but now since you didn't fill the axle intending on oil in the hubs, you wind up low in the center section...
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Old 02-27-2002, 11:38 AM   #14 (permalink)
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I have a Warn FF on my 9", and have no leaks using just silicone, even without the O ring. Id run the hubs in gear oil, due to the above stated reasons
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Old 02-27-2002, 11:44 AM   #15 (permalink)
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Cornjeeper- your seal idea will work, I didn't know the shaft dia would have to neck down. I cut the flange off of that 9" housing and you will have to butt weld the FF flange on because housing doesn't have uniform tube thickness and has a big ass welded seam.

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