is axle shaft to short to be used? -
View Poll Results: Is .68" of gear contact enough?
Yes, it should last for years. 1 33.33%
No, you need to spend a bunch more money for a new one. 2 66.67%
Voters: 3. You may not vote on this poll

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post #1 of 4 Old 03-10-2011, 09:47 AM Thread Starter
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1983 CJ7 
Join Date: Mar 2010
Location: Richmond, VA
Posts: 19
is axle shaft to short to be used?

I am completing the '83 CJ7 build my son started. He had a salvaged Dana44 axle which I had shortened and then I ordered a custom length chrome/moly steel axle shaft from AlloyUSA. My measurements were off. It was 3/8" too long for the spindle to mount on the knuckle. I shortened it using a lathe and a hacksaw. That metal is tough to cut, especially the outer layer! It again seemed too short and I cut another 1/4" off, this time spinning it on the lathe but using a grinder with a cut off blade and finishing with a hacksaw. Much faster and still a clean cut. Now I think I didn't push the shaft it all the way past the oil seal when I checked its length, as it is now a bit short. There is only .68" of gear contact, judging from oil marks on the splines. Looking at other axle shafts, there seems to be about 1.2" of contact normally.

My question is whether .68" of gear contact is enough, or if I have to buy another axle shaft. I have written the company, but would like to learn from the experience of others. The CJ7 will go off road, but nothing too radical.

Thanks, Robert

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post #2 of 4 Old 03-10-2011, 09:51 AM
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1983 CJ7 
Join Date: Jan 2011
Location: Jacksonville
Posts: 105
thats a good one... I say run it till something breaks.

83 CJ7 151 Iron Duke, 4" YJ lift 33"BFG, Alloy one piece axles.

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post #3 of 4 Old 03-10-2011, 10:24 AM
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1982 CJ7 
Join Date: Jun 2010
Location: Marysville, WA
Posts: 5,508
Move the inner C in enough to make up the difference. Running a shaft with that little bit of contact area is asking for trouble down the road. Do it right once and be done. Something to remember, the front shaft actually moves in and out a bit as you turn, and will decrease the contact area even more.

Beat it to fit, paint it to match!

Wheel, Wrench, Repeat.
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post #4 of 4 Old 07-15-2011, 02:34 PM Thread Starter
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1983 CJ7 
Join Date: Mar 2010
Location: Richmond, VA
Posts: 19
I'll play it safe, wanting the Jeep to be as good as I can make it. I ordered another inner axle shaft, which should arrive today!
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