No Power to Rear Wheels

I agree with you about the taper. I was referring to the the interface between the cup and housing being marred up, not the cone and axle.
 
Thanks for clearing that. As I was reading it, I thought you might be referring to the housing bore...

On another item, where the one bearing is now on the flat of the shaft, a seal is supposed to ride. The can see the second smaller bore inboard of the bearing cup bore. Smoothing that area is good two fold. One as you say to reduce stress risers and second to extend the seal life.
 
Thanks, that makes sense, I would have never considered the life of the seal.

How critical are the thrust blocks? I have one of the two, although its in rough shape and I can see where the pin broke. I checked the carrier for the remains but I didn't find anything. I'm considering machining one if I cant purchase replacements. I am also curious how important they really are to the operation.

As for the axle(s) themselves, one of them hangs out 1/4" more than the other (without the thrust block installed) when just inserted as far back as possible. Is this normal? I am thinking its fine and will be compensated for when I install everything, and all torqued down?
 
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