working on my mud truck today it is a 1979 ford f150 swb 4x4.
has dana 44 front c6 np205 and the 9 inch

while assembling my 9" rear differential i noticed my pass side axle will not go in all the way.the driver side goes in perfect

i have a cheapo spol which is splined all the way through but had a closer look and the splines in the spool DO NOT come out to the edge of the spool causing my axle not to go in all the way because my splines are not further towards the outside enough.

i come up with 3 solutions with your guys help i hope i can figure this out,the truck is on a time period.not rushing tho.

1 is can i get a machine shop to furthen my splines on my axle about an 1" to make sure.

2 is can i order custom axles (aftermarket chrome-mo's) and get them to fabricate longer splines as well

3 is to get a machine shop to thin the diameter behide the splines on the axle shaft.


i know number 3 will work because i had a junk axle shaft i ground the diameter thinner behide the splines and now it goes it all the way.this was done with a hand held grinder just to have the rear finished and sitting and waiting till i figure out what to do about the pass side axle shaft.

can you guys tell me if it will ruin the temperament on the axle shaft if i get it ground or machine some longer splines into it?

thanks a bunch