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Old November 12th, 2010, 09:31 PM   #1
95Bronco
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Default Minumum axle to carrier clearnace question.

Long story short I need to have the ends of a carrier opened up to accommodate a larger axle shaft.


What is the minimum clearance between the axle shafts, and the ends of the carrier.....(by ends I mean where the carrier rides in the carrier bearings)

I don't want to have it opened more than is absolutely necessary.
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Old November 14th, 2010, 08:29 AM   #2
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Here is a picture. I need to open up the ID in the case like in the picture.

How much bigger should this bore be than the axle shaft size?

Currently has a 1.31 shaft running through it and want to run a 1.5" shaft through it.
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Old November 15th, 2010, 05:33 PM   #3
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Originally Posted by 95Bronco View Post
Here is a picture. I need to open up the ID in the case like in the picture.

How much bigger should this bore be than the axle shaft size?

Currently has a 1.31 shaft running through it and want to run a 1.5" shaft through it.
So you have a 30 spline shaft and want to upgrade to 35 spline?

Out of curiosity, what are you going to use for gears inside the case?

I would say you'd probably have to be in the neighborhood of 1.6" for the bore diameter, at least. The problem is how thick with the hub on the case be where the bearing rides?
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Old November 15th, 2010, 05:39 PM   #4
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I am no expert on the subject but since you haven't gotten any other advice. I don't see why you would need any more then .01-.02 clearance. As long as your axle tubes are straight there should be no reason to have any more then that. The Spider gears should keep the axle centered and the axle should never be able to make contact with the carrier.

EDIT: How much clearance is there now?
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Old November 15th, 2010, 09:47 PM   #5
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Quote:
Originally Posted by jeepitupyo View Post
I am no expert on the subject but since you haven't gotten any other advice. I don't see why you would need any more then .01-.02 clearance. As long as your axle tubes are straight there should be no reason to have any more then that. The Spider gears should keep the axle centered and the axle should never be able to make contact with the carrier.

EDIT: How much clearance is there now?
I'm also no expert by any means, but I would think 0.10" to 0.20" would be too tight...that means a clearance of 0.005" to 0.010" at any given point, and when the diff gets hot, and the shaft swells, along with the I.D. getting slightly smaller from the heat, I would bet it would close that gap and sieze pretty quickly...I would guess it would need to be about 0.100" larger bore then the O.D. of the shaft (0.050" clearance)...but again thats just a guess ( really just agreeing with Jeepers Creepers)

I would measure a few stock setups to see what the clearance is, or call some aftermarket axle/shaft suppliers or builders and ask them
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Old November 16th, 2010, 02:42 PM   #6
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I will for sure take more measurements as I've got a 60 and a 50 carrier.

I'm working on a Ford TTB with D60 parts, and need to keep the diff cheap until after the axle is built and in.

Turns out there is enough room for a 60 shaft in the 50 carrier, and with some minor work a 60 side gear fits into the 50 carrier. Making a 35 spline TTB D50.


I also understand that a D44 carrier will bolt right into a D50, and 50 gears will bolt into a D44.

This would be a way to upgrade as you go on a D44. Add some big 35 spline shafts and a modified open carrier with D50 gears, then down the road, swap out the open for the D44 35 spline ARB......And I guess ARB is going to come out with a 35 spline D50 unit in a year or so.
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Old November 18th, 2010, 11:28 AM   #7
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I also understand that a D44 carrier will bolt right into a D50, and 50 gears will bolt into a D44.
The Dana 50 carrier has been discontinued. A modified Dana 44 carrier has been used for years to replace it by doing what you're asking about but I don't know what the ID of the carrier bearing hub has to be machined to. Best bet would be to find a D50 carrier and measure it. You shouldn't need to machine all the way down, just enough to clear the OD of the non-splined part of the axle shaft.

You will need a 3.73-down D44 carrier.
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Old November 18th, 2010, 12:17 PM   #8
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You might search on pirate4x4, it should be similar to the clearance needed for boring spindles to accept 35 splines, although you've got less length, so its not as critical. I agree with the guys above, don't go with a very small clearance like 0.01 or so. A lot of people have friction welded their shafts to their spindles doing so.
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