Dana 27 rear axle won't slide back in

[Scout survivor]

I have a 64 Scout 80, Dana 27 axles front and rear, limited slip differential on rear. I pulled out the rear axles, replaced the bearings (press fit at a machine shop to the near exact location of the original bearings. I made sure to use the exact replacement bearings. Now when I slide the axle back in, it stops short of seating the bearings- this is true on both the passenger and driver side. Turning the drive shaft does turn the axles (and vice versa, turing the axles turns the drive shaft), and when I push the axles in, the splines do seem to seat. It took me several months after getting the axles out to the point where I am now to trying to get them back in. The distance needed to fully seat is about the width of the bearing. The races are not in the way. What is the problem and how do I fix it- thånks!

 

[FDChappie]

Sounds like the splines are not going into the pinion gears. Try to shine a light down the axle tube and see if the gears are out of position.

 

[Scout survivor]

And if they're out of position, how do I get them realigned?

 

[FDChappie]

Pull the diff cover and you'll have access to the gears. Good opportunity to check for random chunks of metal and loose bolts while you're in there.

 

[Winchested]

There is buttons that go in the diff. If they're out of place your axle shaft won't go in.

 

[Zaedster]

There is buttons that go in the diff. If they're out of place your axle shaft won't go in.

This.

 

[Scout survivor]

Thanks for the help. Here's the outcome as an fyi. The axles are in and it required taking out the differential case because once I did that I found I had 2 separate problems. I found that (1) the inner spines and outer splines on the passenger side somehow got slightly out of alignment which blocked that axle from seating (the axle hung up at the interface between those splines). And on the driver side, the thrust button was dislodged. Once I figured those things out and fixed them, the axles went in smoothly after I replaced the differential case. Those thrust buttons are a pain to keep in correct position to get the axles in!

Along the way, I snapped the head off one of the diff cover bolts (the one at around 10 o'clock). Now, having tried to drill it out and using an extractor, I handily snapped of the extractor in the hole I drilled in the bolt! If you've got a suggestion for somenthing other than welding a bolt on (I don't have a welder) I'd appreciate it.

 

[Winchested]

Thanks for the help. Here's the outcome as an fyi. The axles are in and it required taking out the differential case because once I did that I found I had 2 separate problems. I found that (1) the inner spines and outer splines on the passenger side somehow got slightly out of alignment which blocked that axle from seating (the axle hung up at the interface between those splines). And on the driver side, the thrust button was dislodged. Once I figured those things out and fixed them, the axles went in smoothly after I replaced the differential case. Those thrust buttons are a pain to keep in correct position to get the axles in!

Along the way, I snapped the head off one of the diff cover bolts (the one at around 10 o'clock). Now, having tried to drill it out and using an extractor, I handily snapped of the extractor in the hole I drilled in the bolt! If you've got a suggestion for somenthing other than welding a bolt on (I don't have a welder) I'd appreciate it.

Other than a real melty blow torch or welder youre prob sol. If its a through hole you may get lucky with a punch and hammer to break up the extractor, this has worked for me as the extractors are pretty brittle.

 

[Scout survivor]

Good news! It's a through hole and I simply punched out the extractor, working from the backside. Now I'll drill it further, clean up the threads and if all strips out, just use a nut and bolt combination. It's at the 10 o'clock position so favorable.