Bent Axle Shaft Ears

[Jimbocker]

Hello all,

I did a search and was surprised that nobody has posted about this issue before...

I'm in the middle of the Dana 30 rebuild on my '77 CJ7 . I went to put new u-joints in the axle shafts, and I discovered that I bent the axle shaft ears a bit when removing the old joints. The bearing caps were pretty frozen in place, so it took a rather large amount of force to break them free.

Anyway, the ears seem to be too bent to put the new snap rings on the bearing caps, so I can't finish installing the u-joints. I have come up with a couple possible solutions:

1. Buy new chromoly shafts, delay rebuild several months waiting on funds.
2. Build a spreader of sorts to push the ears out while applying generous amounts of heat to the ears.
3. Go to a driveline shop and see if they can install the u-joints.

Currently, option #2 sounds the best. I don't need the shafts to be super strong yet, I just want to be able to put the dang thing back together. Hopefully after I have the jeep put back together I will upgrade the axle shafts, but in the mean time I'd like to just reuse the stock ones.

Has anyone else solved this problem? Any suggestions?

Thank you,
Jeff

 

[Lumpy Grits]

Post up some pictures so we can better help you.
LG

 

[Jimbocker]

I'll do that tomorrow. Thanks!

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[Torxhead]

In my CJs toolbox, I do carry a spreader which consists of 1/2" all thread, big washers and nuts. Have used it a few times, usually when a u-joint breaks it will spread the ears and require closing up to remove it from the housing. I would suggest against using heat though as it can weaken the shafts ears. All of your options do sound good so take your pick. The stock axle shafts are pretty weak with a big set of tires.

 

[mtnwhlr]

.
3. Go to a driveline shop and see if they can install the u-joints.
f

I would take it over to Drive-line specialists on 49th st in Boulder. They are great they have done lots of things for me over the years.

 

[Jimbocker]

As promised, here are some photos. This is only one of the shafts, but they both have the same symptoms. Notice the snap ring on one side and the bearing cap protruding on the other.

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