Im running into a problem with my dana 44 front i rebuilt it, backlash is good,it has good pattern. Everything moves good untill i try to tighten the axel shafts down. I put the caliperbrackets on then the spindle the dust cover for the rotors was screwed up so i tossed it. When i tighten the spindles down the axle shafts dont move. You cant even spin the pinion without excessive force. Does anybody have any ideas?

 

FTE members may need more information to find a solution to your problem. Did you replace either long /short inner axle shafts or outer stub axles. Did you stay with the 5 on 5 1/2 bolt pattern or did you put 3/4 ton brakes / rotors by chance on the coil spring 1/2 ton front axle. If you purchased new inner axles I believe 3/4 and 1/2 tons are slightly different in over all length. This could be the cause when spindle is tightened to knuckle? Just a couple of thing you might check out. I ordered after market axles for a front axle build and was informed that the 3/4 ton Rev rotation 44 had a longer inner axle dimension than bronco or 1/2 ton PU's. Good luck and keep posting with additional info to the fix.

 

They're the same axles from that housing just took them out rebuilt differential new seals and bearings but they just wont bolt back up

 

If all parts are the same did you also replace the seal and washer that ride at the back of your spindle on the stub axle that keeps the inner needle bearing sealed from debris. Just wondering if the problem might be at this location causing the spindle to jam the axle u-joint into the axle housing and not turn properly. Is there any movement at knuckle u-joint with the spindle tightened. The axle can move slightly if i recall until snap ring is installed with inner hub gear. Does this problem only occur when the hubs / rotors are installed properly. Have you tried a washer in place of the dust shield you stated was damaged and tossed to see if the axle will turn? That's all that I can think of to check for now. Good luck.