I am putting a full spool in my Bronco and ran into a problem. I couldn't get my pass side axle in all the way. After a while I took everything apart again and measured everything. It seems that my axle splines on the pass side are not long enough. I still need about an inch to get the axle all the way in. Anyone know how much it would be to have the splines cut a little longer? Are there any problems with doing that? Did Ford make different length axle splines for the 9inch? Are the trac loc axle splines shorter than the ones for an open diff?
I just need a cheap way to fix it but one that will last. By the way i measured my spline length and it is about 1 and 3/4 inchs I need it to be 2 and 3/4.

 

are these axles the stockers?

yes ford made at least 2 different widths of 9" and i am sure more than that.

you are really not supposed to cut splines in, rather have them rolled in when the axle shaft is still red hot in the manufacturing facility. however i have heard of plenty of people doing it and havin great success. i'm sure you could cut splines in (take it to a machine shop, please dont use an angle grinder, lol) and it be fine.

-cutts-

 

> Anyone know how much it would be to have the splines cut a little longer?
> just need a cheap way to fix it but one that will last

With a spool, you will want to buy a new axle with the correct length splines already rolled into the axle shaft and heat treated after the splines are added. To do it any other way means micro-fractures (cutting) and a non-heat treated surface (soft) that will surely fail under the stress of a locker or spool.

Trying to get a 3rd member out with a broken axle shaft in it is always a treat. You have to put a big bar down the tube and hammer the axle shaft that remains in towards the pumpkin. Then once the 3rd member is out, then you have to remove the axle shaft you just wedged into the side gears (or spool for you).

Last time I checked an axle was $115-$130 for a 9 inch.

That being said, I would try a van 9 inch axle before I wasted my money on a new axle. They are likely to be 31 spline and 1.5 inches longer then a stock truck axle because they have a 3" wider track drum to drum.

 

Something is wrong here, like that isn't the correct axle for the housing. I am assuming this is a full sized bronco in your gallery, the axle shafts should be the same length side to side, and a spool uses the same axles as an open differential so if it's not long enough or too long something else is wrong somewhere.

 

The axles are the same from side to side. Ley me try to explain this a little better. The axles are the correct length. However on the pass side the splines do not go far enough down the axle. I thought that the spline on an open 9 inch where about 3 inchs long. where as the splines for a trac loc are 1 and 3/4 inchs. I talked to a guy from an axle shop today and he said that there are a few full spools for the 9 inch that are splined closer to the end towards the bearing. Anyone have an axle out of an open diff that can measure the splines?

 

77 open diff 1-9/16", 81 trac loc axle 1-5/8" thats the two sets I have sitting here.

Edit to add, teh superiour aftermarket axles I put in the truck had the approx same length splines when I matched them up before i installed them to make sure the length was right.