I finally found a 60 front, but it is in sad shape, so I'm doing a complete rebuild. When I put my u-joints in the axles the inner axle fit pretty loose around the axle cap. It was loose enough that I didn't have to hammer it in, just shove hard by hand. I took a 2 pound sledge a smacked the ears of the axle around were the cap goes. This improved the fit to the point where I neeed to press the cap in with the vise. I have never seen one fit that loose before, and I don't know if the hammer tuning did anything for it or not. I 'm just concerned that it will spit a cap out when I gets a good load on it, cause I know with a 60 front I'm only going to want use it harder. (Why else do you want one?)

 

i would look at getting some new shafts....sounds like those axles have been beat on prett yhard and the ears have ovaled out a bit...to keep the caps from spinning...losing the c clip and spitting out...you can either tack weld them in(shortens life) or machine the axles to take full circle clips instead of c-clips...if it were me i would buy new inner shafts(that neck up) and get 35 spline outers and some life series joints and be done with it. go ahead and run full circle clips.

in the meantime...if you plan to wheel it hard, just put 2-3 tacks on each cap and wheel the **** outta that 60

 

You can also take a center punch and and make marks all the way around the inside of the yoke to tighten it up.

 

After I got done beating on it, it seemed to restore the press fit. I was wondering if anyone else had ever seen this (and knew if it would stand up). Your right this axle was used about as hard as one could be. Out of a former well truck (87 F350 single wheel, it already has non neck down inners if they turn out to be worth a hoot). It lived in mud its whole life. I don't think they ever unlocked the hubs. About the only thing savable is the housing, knuckles, etc. I already have bought new outer axles, the old ones were worn on the end because it was ran with bad spindle bearings which let the shaft wobble. I have new warn premium hubs for it as well. One of the wheel hubs is junk from running on a locked up bearing, as well as the spindle. The axle tubes were completly filled with dirt and gear oil mixed. I bought it at the right price, but as it stands I'm still going to have some dollars in it by the time I but new gears (anyone want a set of 3.55 60 gears?)and the whole nine yards. No one would know its the same axle now, I steam cleaned the heck out of it, inside and out, wire brushed what the steam wouldn't shake, and painted it with rustoleum. I may wind up replacing the inner axles but that adds major expense to this project.