Manual Hub Problems?

[oldmech41]

The tire shop did not get the manual hub splines properly engaged to the drive axle splines. I corrected the problem but now when the hubs are engaged and I turn a corner the drive axle slides toward the differential and the spline disengages making for a horrible noise. I cannot see a grove in the drive axle splines for a retaining ring. Does anyone know what is supposed to keep the splines of the drive axle engaged to the hub internal splines?

 

[RangerX]

What work did the tire shop do? Just tires, or did more than that?

 

[MrShorty]

There should be a groove and a C-clip in the outer end of the axle shaft, just inside of the hub that keeps the axleshaft from "sucking" into the spindle. Sometimes, one would need to push on the axle from the back side to push it out far enough to find the groove. Is it possible the tire shop took this off? Is it possible they forgot to put it back on?

 

[oldmech41]

The tire shop only did a tire rotation. I have removed the spindle to look for a groove but I cannot find one. The left side looks the same as the problem right side but I am not having any problem with the left. I could use a good detailed exploded view but they seem to be hard to find.

 

[natenkiki2004]

Take a look at this, this is the axle with the spindle removed:
https://dl.dropboxusercontent.com/u...rer/Pictures/CameraZOOM-20140913121736552.jpg

You can see just at the end of the splines, there's a gap. That's where the c-clip goes to prevent the axle from sliding inward towards the differential.

This is what the hardware looks like:
https://dl.dropboxusercontent.com/u...rer/Pictures/CameraZOOM-20140913121802973.jpg
There's 8 pieces if you look carefully. Right next to the handle of the grease gun is the c-clip. It goes in that groove. It can be a pain to get in sometimes due to the clearance of the washer (item to the left of the clip in the picture). I found that turning the knuckle all the way to one way and sticking a pry bar in the u-joint and prying on the joint to pull it out of the diff gave me enough clearance to get the c-clip in. In my case, I think it was just too much grease creating an air pocket preventing the axle from coming out all the way.


Here's the whole thing assembled:
https://dl.dropboxusercontent.com/u/464376/vehicles/1994 Explorer/Pictures/2015-11-20 13.35.14.jpg
If you look carefully, the c-clip is barely taller than the splines for the axle but it's there.

 

[RangerX]

Here's an exploded view: http://www.therangerstation.com/tech_library/pdf_documents/Dana_Ford_35.pdf MrShorty is talking about parts 61 and 62.
Then look at this excellent write up on front brakes, in the first few pics, it shows the snap ring and thrust washer: http://www.explorerforum.com/forums/showthread.php?t=122696
<edit> too slow, Nate beat me to it!

 

[FR-425]

Amazing shop work these days, can't rotate tires without screwing it up.

They no doubt knocked the c-clip off trying to figure out how the clock the hub back on.

Probably saw it laying on the floor and gave it the ol' shoulder shrug..

 

[oldmech41]

Thanks to all !!! I have been searching quite some time for these answers. I have had the spindles off many times prior to the tire shop work and the axle retainer and washer have never been installed on either side (I purchased the Explorer in 05 with 135,000 miles ). I now think that the problem may not have been as much the tire shops fault, but more just the amount of miles (368,000) that caused the problem to finally show up. Thanks Again to all !

 

[RangerX]

Maybe they have been missing since a previous owner converted to the manual hubs.
Do you plan to find some and install? I know the star washers are available, you might have to try Ford for the clips.