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Just finished the passenger side of my dana 44 axle rebuild and when I put the manual locking cap on the end of the hub it won't seat flush.
It has about 1/16" gap between the hub and the cap. I took the locking gears out and the cap will sit flush then. And the locking gears appear to sit all the way in.
I can get both inner and outer clips in also
What should I be looking for to cause the interference?
Are you using the stock hubs, or did you get aftermarket replacements (Warn, Mile Marker, etc.)? I put Mile Markers on mine, and they don't seat completely flush, but everywhere I've read said this is normal and they're still sealed so water can't get in.
I'm using Mile Marker also. So I guess its good it's not just mine. They seem like they should seal ok. I don't plan on any extreme mudding or water crossings so I'm not too worried then.
Well I'm not happy now. The drivers side cap mounted flush with the hub. I'm almost done with the front now. Just need to replace both tie rod ends, steering stabilizer, and brake lines and calipers.
Then onto the back!
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