[Apocalyptica]

Is there not supposed to be a collar to lock the intermediate shaft in place thats located in the pumpkin? I recently did my front seals and never removed one, im having issue with 4x so i opened the CAD and seen the splines on the end of the intermediate are wearing and that shaft can push in towards the pumpkin roughly 3/8"-1/2". Ive looked at parts list and one shows one but its discontinued and looking at new shafts i dont see a slot for a collar or the collar. When i engage 4x4 the front end makes a horrible banging noise, any help is appreciated.

 

[bigfish95971]

The collar is there to slide from the intermediate over the outside axle splines. There is no(only a few thousandths) between them. The intermediate floats and will wasily slide in and out if the outer stub has been removed. It also has a pilot end that goes in the end of the stub and has bushing in there also.

 

[Apocalyptica]

Yea, i understand how the CAD works but i was seeing if there was a collar on the shaft end thats in the carrier assembly in the pumpkin to keep it from moving so much. Im just not quite sure where ive acquired this much play in that intermediate shaft. Im opening it up this weekend to see whats going on, would be nice to have 4x4 for the approaching winter. Cheers

 

[bigfish95971]

There should be no play in the intermediate shaft. It bottoms out in the drive gear inside the carrier. Only collar is the CAD.

 

[u2slow]

It probably contacts the cross-pin in the carrier before bottoming the splines in the side gear.

I have a cad60 in pieces I can look at later today.

The quick'n'dirty one piece shaft swap is a 99-04 super duty (Dana 60) and a 35 spline side gear. You have to figure out a seal though.