Super Rough Time with Reproduction Dana 25 parts

[Greg]

All

I've been rebuilding my front axle this summer. It's getting all new seals, new axle shafts and flange bushing.

The Omix inner axle seals had 0.030 inch of interference between the can and the axle tube. Not sure if this is the correct amount but they were near impossible to install square.

I have 4 Omix flange bushings. Only 1 has enough clearance in the ID once pressed into the spindle to accept the axle. The other three are too small. The one that fits is missing the grease groove.

The after market Spicer axle shafts bind up at a very small steer angle because the area around the grease fitting on the u joint hits the axle when turning.

[Greg]

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[Greg]

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[squidtone]

Hi Greg,
Wow that's too bad about those parts. Why did they furnish the axle shaft with a grease joint if it's going into a enclosed knuckle? The typical non-greasable u-joint has more room for angles... and stronger too...
I can't quite read what angle you're limited too on the card...
Otherwise, I've seen folks grind yokes and hard parts to gain a little more room on u joint angles on lifted trucks and Jeeps...A good stone on a 1/4 grinder will make short work of it.
But I get your point...aftermarket parts need so much work to get them to work.
I recently bought inner seals from Walcks, and they fit nicely into the axle housing. But Walcks bags were unmarked...I don't know who made 'em.
Well, good luck!
dave (squidtone)

[oldtime]

So once again it's another vote for Omix Adda = instant junk !

The maximum steering angle is mainly due to the joint design.
It has never been a clearance issue for the Bendix, Rzeppa or Spicer type front axle shafts.
Grinding is not required.

The articulation for the various shafts is:
Bendix type = 23* maximum working angle
Spicer Type = 27-1/2* maximum working angle
Rzeppa = 29* maximum working angle

Because of the greater working angle and several other factors I always prefer the Rzeppa type joints.
In fact I cannot use a greater steering angle without my STA 6.50 x 16" tires rubbing.
At maximum steering angle of 29* my tires just begin to hit on the leaf springs.

There are NOS Rzeppa shafts available on eBay.
I cannot fathom one  buying Omix junk when other, better options exist.

That said Rzeppa type front axle shafts may not be ideal for everyone.

[Greg]

The axles are actually crown. Crown was very nice on the phone and looked at their axles they have in the warehouse. They do the same thing. They said I should ask the store I bought them from for a refund or wait a week or so for them to figure out a solution. 

How were you able to figure out the bend angles based on axle type? My FSM lists the angles as a function of serial number.

I put the axle back under the Jeep without axle shafts for now. What is the secret for bending the wheel bearing lock washers over the outermost nut?