I seriously broke my front end somehow. I chewed up the right front hub (and had no 4wd - found that out the hard way). I took the hub cover off, and the grease is full of metal particles. The gears in the hub itself are stripped completely off.

So I bought a set of milemarker hubs for it, thinking I'd just swap in the new hubs and all would be good. I figured the hub got wrecked when I drove 300 miles with that side locked in - I think the neighbor kids locked it in, and I didn't check before I left for camping last weekend.

I took the old hub out, and I couldn't get the new one in because the shaft isn't centered in the rotor. I don't think the bearings are shot, because I drove it home 300 miles after seeing this, and there is no sign that the bearings are shot. No vibration, no shrieking, no funny noises.

Have I bent an axle shaft? I noticed that the shaft rubs against the I-beam where it 'threads' or goes through the beam - is this normal?

I haven't jacked it up and put it in 4x4 to see if the shaft spins like it's bent or if it spins like the rotor isn't seated right. That's next.

Anybody ever seen anything like this happen?

 

How far off center is the axle? Can you move it to the center with your fingers? If so, you probably will have to mess with it to get the hub to line up. If not, tear that thing down to the spindle. Make absolutely certain that you haven't had the spindle bend or break loose from the knuckle. The spindle is bolted to the knuckle and can be removed to gain access to the axles so they can be removed from the diff. housing. Its an unlikely scenario but not beyond the realm of possibility. Is the front diff. "open" or do you have an LS or locker in the front? I only ask because it could account for the trashed splines inside the hub. Either way, if the spline on the end of the axle has been damaged you will want to remove it and have it checked out by a machinist. Sometimes there is enough spline left that you can reuse the axle. Other times you are replacing the axle. You mentioned the axle rubbing at the pass-through on the traction beam. Is the wear significant or just a light scuffing? At full suspension travel, the axle can get close enough to brush the flash rust off of it. Still sounds like a spindle problem to me though.

 

Thanks for the reply, greystreak. I can't move the axle with my fingers. It's about 1/4" off. I also tried lightly prying it back in place at the u-joint behind the knuckle. Moving the steering wheel didn't help, either, so I don't think it's loose.

I just did ball joints on the driver's side about a week ago, so I'm real familiar with the parts you're talking about. Either way I'm pulling it apart (hopefully tomorrow) and seeing what the story is.

It's an open, stock D44, 3.54. The end of the axle itself doesn't look damaged. I think what happened was the axle grabbed a hold of the inner hub 'ring' and ground away at the outer hub ring.

The wear at the pass-through doesn't appear to be light scuffing. From what I can see, the axle rubs against the beam constantly. It's worn away a contact patch about three inches long on the axle. We're not talking full suspension travel here, either.

How's the new ride? Hope they caught those lousy you-know-whats who torched your truck.

 

Andym,

Yes, they caught the lousy SOB. I only wish I could have gotten a few minutes with him.

Anyhow, the new one is really nice and I discovered yesterday that I have the factory LS in the rear (happy dance).

As to your dilema, good luck. Hope its not real serious but that wear patch on the axle is rather odd. Let us know what you discover.

 

Found the problem. I just wish I didn't tear it down to the knuckle to figure out what the problem was. The wear patch on the axle was an important clue.

Somehow, I have bent the right front I-beam. Forward. As if it caught on something while I was going backwards. The beam bent forward far enough to scrape against the axle, pushing it off line with where it should be. It's this stress that is pushing the axle off center in the rotor, and it's this off-center-ness that chewed up my hub.

Now my only question is, is it worth trying to bend the beam back? I'd have to take it to a shop to do it. I don't have anything NEAR strong enough to bend a suspension I-beam. Or should I head to the boneyard tomorrow (the truck still drives fine) and pick out another front axle assembly? How much work is involved with swapping out a Dana 44?

 

you are in luck maybe I am no expert but I have just taken the front end off my parts truck and the right side is a piece of cake
when you go to the bone yard make sure the brake caliper is the same, some have HD ( 2 slide rails) others are 1 slide and a bolt on clip kinda thing( don't know the right name) anyway pick the one thats the same as yours and all you need is the right side
disconect shocks(oh ya make sure it has the same shock setup as your(1/side or 2/side) then remove caliper or just cut the brakeline then unbolt swaybar and radius arm and coil spring then 1 bolt at the I beam pivot and pull it out ,the slipjoint just pulls apart. your lookin at 1 hour max to pull it. the gears are all in the left I beam so if the coil spring is the same it is a day project but you may want to change the coil to the origional from your truck so they are matched.
good luck

 

I actually went to a yard yesterday after deciding I didn't want to risk it and just have the beam bent back.

There wasn't much left of the truck I took it from. The axle was cut clean off, right through the radius arm bracket. It had dual shocks, nice looking springs, and the date on it was '94. I would have taken the whole front axle if the radius arm brackets hadn't been cut in half and the sway bar wasn't broken in half. I only took the beam, though. Not bad for $40. I didn't notice the brakes, but I'm going to use my steering knuckle anyway.

This will be a good project for next weekend! Thanks!