Stripped front left axles splines in diff (35 TTB)

Oregunner · Mar 21, 2018

Sorry.. put this in the wrong thread. Howdy all, I'm Dan. I have wheeled a 92 Ranger for 15 years in the PNW ... First time joining a forum, excuse my mistake

Hi guys. My left front axle splines stripped where it goes in the carrier. Its only about a 1/2" on the end, which leads me to believe that it wasn't fully engaged into the diff leading to the failure.

Any ideas on why the axle might have worked its way out? I order parts to replace it, but want to make sure that I solve the issue.

Now I have to figure out how to get all the metal shavings out of the diff. The Ected locker sucked up most of the shavings. Should be a fun job :annoyed:

I appreciate any feedback. Thanks!

adsm08 · Mar 21, 2018

Bad circlip didn't hold the shaft in.

Oregunner · Mar 21, 2018

As far as I can tell from exploded views, the left front axle doesnt have a C clip in the diff

Oregunner · Mar 21, 2018

I think I discovered something. In the exploded view of the Dan 35 TBB, it shows the axle shaft spacer ( I googled it, looks like a splined washer.. part number FOTZ3B458A). I dont have one of those in my assembly. Damn mechanic that owed me money worked on this spindle 6 years ago must have pitched it in the trash.

However, it seems that this would only keep the axle from going too far in the diff. Does it also ride on the edge of the hub to keep it from coming out of the diff?

adsm08 · Mar 21, 2018

Oregunner said:
I think I discovered something. In the exploded view of the Dan 35 TBB, it shows the axle shaft spacer ( I googled it, looks like a splined washer.. part number FOTZ3B458A). I dont have one of those in my assembly. Damn mechanic that owed me money worked on this spindle 6 years ago must have pitched it in the trash.

However, it seems that this would only keep the axle from going too far in the diff. Does it also ride on the edge of the hub to keep it from coming out of the diff?

No, that washer can't do much to keep the axle from coming outward. It is held in place by another circlip that clips around the axle.It can keep the axle from riding in, and it can keep bearings and such from riding out, but it can't keep the axle in. The axle wouldn't fit through the spindle, but IIRC there is another clip inside that is supposed to hold it in the diff.

Jim Oaks · Mar 22, 2018

When you say left, you're talking about the drivers side right?

ericbphoto · Mar 22, 2018

Jim Oaks said:
When you say left, you're talking about the drivers side right?

Oh. Here we go again...

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adsm08 · Mar 22, 2018

Jim Oaks said:
When you say left, you're talking about the drivers side right?

I hope so. That's how my post assumed things.

BlackBII · Mar 22, 2018

No C clip on the drivers side axle shaft in the diff. There is one on the small passenger side shaft.

The Drivers side shaft is kept in place by the seal and metal oil slinger (Part number Dana Spicer 50492) pressing up against the backside of the spindle as best as I can tell.

Drivers side shaft in the middle, Passenger side on top

Oregunner · Mar 22, 2018

Jim Oaks said:
When you say left, you're talking about the drivers side right?

Correct, drivers side front axle

Oregunner · Mar 22, 2018

Axle shafts are nearly extinct for the 35ttb. I've been looking like crazy and finally found 1 brand new OEM inner half shaft. Last one on the shelf. I've beat the piss out of those axles... surprised this is the first axle failure I have had in 15 years. Only due to the damn axle creeping out though

I will take a complete inventory of my outer axle assembly and compare it to the Dana exploded view one more time just to be sure.

Also, Warn claims to not have the hub locknut upgrade kit anymore. Anyone have a home fix for keeping those damn spindle bearings from loosing up?

Jim Oaks · Mar 23, 2018

adsm08 said:
I hope so. That's how my post assumed things.

Just wanted to make sure. I can see where the passenger side could slip in and out, but not the driver side.

BlackBII · Mar 23, 2018

Oregunner said:
Axle shafts are nearly extinct for the 35ttb. I've been looking like crazy and finally found 1 brand new OEM inner half shaft. Last one on the shelf. I've beat the piss out of those axles... surprised this is the first axle failure I have had in 15 years. Only due to the damn axle creeping out though

I will take a complete inventory of my outer axle assembly and compare it to the Dana exploded view one more time just to be sure.

Also, Warn claims to not have the hub locknut upgrade kit anymore. Anyone have a home fix for keeping those damn spindle bearings from loosing up?

The axle shafts can be easily found in Junkyards. The ones in first gen explorers are usually in the best shape because not very many people used 4 wheel drive in those.

We've discussed the spindle locknuts a lot on this forum. The biggest issue is that the interior diameter of the hubs is so small that it makes using anything but the factory style nuts difficult. But, make sure the pins on the inner nuts are not sheared off, make sure the washers' tab isn't sheared off and torque the outer nut to 225ft-lbs and not the standard 150 and you should be good. If you do need to replace the nuts, use Dana Spicer 28068X, and not Dorman or any other brand. They are cheaply made and the pin and washer will fail.

http://www.therangerstation.com/forums/showthread.php?t=161361

Fordracing232 · Jul 25, 2023

I know this is a old topic but when you replace universal joints on the passenger side axle I caught very little info on how to properly resolve it I was told the u joints had to be clocked a certain way if not it would cause premature wear on the unjoints and not only that it would eventually wear the splines off the axle anyone have info on that

ericbphoto · Jul 25, 2023

Fordracing232 said:
I know this is a old topic but when you replace universal joints on the passenger side axle I caught very little info on how to properly resolve it I was told the u joints had to be clocked a certain way if not it would cause premature wear on the unjoints and not only that it would eventually wear the splines off the axle anyone have info on that

Any shaft with u-joints at each end, they must be phased properly.

Stripped front left axles splines in diff (35 TTB)

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