Can't get washer on D35 axle shaft

[GingerKid]

In the process of swapping hubs on my truck, I noticed that the washer on the axle shaft that goes on before the c clip is missing. I also can't pull the axle shaft out far enough that I can get the clip on with the washer on the axle. Any ideas on why this is happening? Also, is this washer something I can get at a parts store, and what name would it be under?

Manual hubs, D35 if it matters.

EDIT: after seeing an exploded diagram in another thread, it seems I'm missing all of the washers. I just have the lock nuts and the c clip on the axle.

 

[4x4junkie]

If the shaft won't pull out through the spindle far enough, check that the axle shim and seal is installed correctly around the shaft behind the spindle (also, check that an extra shim didn't end up behind there somehow).

If you can't get the splined thrust washers at a dealer, a junkyard might be your best bet.

 

[Sasquatch_Ryda]

There are also 2 types of spindle seals that you can get, one that is just a rubber lip seal, the other has a plastic collar on it. I know on my truck if you use the one with the plastic collar you can't pull the axle out enough to get the splined washer on and the c clip.

 

[GingerKid]

Could this happen from the seal going bad? The PO had somehow grenaded the manual hubs, and decided to just gut the internals instead of fixing them. As far as I know, the spindle seals haven't been changed since then. I imagine that was when the washers got lost too.

 

[Will]

There are also 2 types of spindle seals that you can get, one that is just a rubber lip seal, the other has a plastic collar on it. I know on my truck if you use the one with the plastic collar you can't pull the axle out enough to get the splined washer on and the c clip.

Didn't know this.

I don't particularly recommend this, but I haven't used washers or clips on mine since about 2005. I haven't busted any hubs (I use 37780s), haven't busted any joints except when my radius arm and axle beam broke. I don't know the reason for that washer in clip, but it seems to be fine without it. Yours will probably break immediately if you leave it out for all I know.

 

[paranger]

i have never ran the washer since i installed the warn manual hubs, has worked for me.

 

[Sasquatch_Ryda]

Didn't know this.

I don't particularly recommend this, but I haven't used washers or clips on mine since about 2005. I haven't busted any hubs (I use 37780s), haven't busted any joints except when my radius arm and axle beam broke. I don't know the reason for that washer in clip, but it seems to be fine without it. Yours will probably break immediately if you leave it out for all I know.

I tried without the washer and clip and kept having issues with the passenger side stub shaft pulling out the hub, thus chewing up the splines in the hub and end of the shaft and losing 4 wheel drive as I don't have a locker in the front.

 

[GingerKid]

I have a similar problem to sasquatch. Every time I engage the hubs, even if the t-case is still in 2hi, I get a grinding noise from the left side when moving. I'm guessing that sound is the axle shaft skipping in and out of the hub splines.

 

[ranger1911]

i just had to replace my passenger side front wheel bearing, it was toast. Couldn't get that damn clip on either, drives fine so far. I'll have a good idea after this fishing trip whether or not it's a neccesary part

I am glad to hear that someone has been fine without the clip though, makes me feel a bit better.

 

[mazdamama]

well, i might be off, but if you guys are talking about that splined washer, i think it is pretty important to have, but if your having trouble getting it to go back on, one thing you might want to try is pushing it up against the splines so that it looks as close to lining up as possible and then putting a large pickle fork over the washer and lightly tap it into place while turning the axle shaft to make sure it goes on evenly. this worked for me anyway. you guys should have seen how warped and chewed up that little splined washer was, but i was still able to tap it back on and it holds just fine doing it this way.