[importsmasher]

I broke the original rear end in my 66 GTO back in high school (1987). I kept the bare housing to one day reinstall. For the last 20 years, I've been running a 3.23 open rear I pulled from a 66 Cutlass. It's the same housing as my original (BOP 8.2 10 bolt). I just had all new parts put in my original housing (3.55 gears, Yukon posi carrier). I put the axle in the car, and went to install the axle shafts from the old rear into the original one, and they are about 3/8 to 1/2 inch too long. They bottom out before the bearing seats in the housing. I know they made wider axles in later years (67 and up I think), but both of these housings measure the same flange to flange.

Do I need to get new axle shafts that are shorter? Can the originals be shortened?

Any help is appreciated.

Thanks,
Importsmasher

[Cammer-6]

just to clarify
these are the same axles that was in this housing?

[importsmasher]

Originally Posted by Cammer-6

just to clarify
these are the same axles that was in this housing?

Yes, many years ago.

[Kenth]

If "the old rear" is the "original one" i can´t see the issue unless the Yukon posi is wrong in some way or the splines on axle shafts are twisted.

[importsmasher]

Originally Posted by Kenth

If "the old rear" is the "original one" i can´t see the issue unless the Yukon posi is wrong in some way or the splines on axle shafts are twisted.

That's what I can't figure out either. The axle shafts are the same ones that came out of this rear end 36 years ago. They've been in a 66 Cutlass rear for the past 20 years. The splines aren't twisted, they're bottoming out. Doesn't make sense. I've reached out to Yukon to see if they can help.

[Cammer-6]

it sounds like the carrier is at fault
Kenth good call on splines being twisted

[george kujanski]

A while back when i was sorting out the current car i have, a friend noticed a wheel on one side would wobble driving. Turns out the car was hit on that side and the axle flange was bent. Bought a new one from Yukon; had the bearing pressed on and it bottomed the same way you state. The axle also came with a collar 9spacer) that gets pressed on similar to the bearing. Turns out the collar gets pressed on first, then the bearing, moving the bearing towards the carrier. Didi that and fits fine.

The whole point is: did Yukon change the diff to accept their axles?

George

[importsmasher]

Originally Posted by george kujanski

A while back when i was sorting out the current car i have, a friend noticed a wheel on one side would wobble driving. Turns out the car was hit on that side and the axle flange was bent. Bought a new one from Yukon; had the bearing pressed on and it bottomed the same way you state. The axle also came with a collar 9spacer) that gets pressed on similar to the bearing. Turns out the collar gets pressed on first, then the bearing, moving the bearing towards the carrier. Didi that and fits fine.

The whole point is: did Yukon change the diff to accept their axles?

George

Interesting possibility, but wouldn't moving the bearing on the shaft make the flange stick out further, and then the brake shoes wouldn't line up with the drum?

I heard back from the supplier, and they said it's not uncommon for axles to need to be trimmed about 1/8 inch to fit their carriers (no idea why, and I didnt ask). Mine needs more than that, but they told me as long as I have a minimum of 7/8 inch spline engagement, I'm good to cut the axles down, so that is what I will do. I'm going to measure more precisely and then cut them.

Thanks everyone for the input!

Importsmasher

[george kujanski]

True on the brake shoes and drum comment, so never mind.

George

[Cammer-6]

so it sounds like the issue is indeed the carrier.
Like the splines arent machined as deep as OEM

[importsmasher]

Originally Posted by Cammer-6

so it sounds like the issue is indeed the carrier.
Like the splines arent machined as deep as OEM

Yeah, that is apparently the difference. I'm not going to pull it back apart to compare though lol.

[Cammer-6]

Originally Posted by importsmasher

Yeah, that is apparently the difference. I'm not going to pull it back apart to compare though lol.

Ask Yukon

[importsmasher]

Originally Posted by Cammer-6

Ask Yukon

I did. They're the ones who told me I might have to cut them down 1/8 inch. BUT.......

I went out to the shop today, to measure exactly how much I needed to cut off, and I noticed there wasn't much room between the wheel seal and the bearing retainer on the axle shaft. I tested that theory, and it turns out the bearing retainer was hitting the seal. That was the solid "bottoming out" i was having. I pulled the seal out and the axle went right in. Upon closer inspection, they builder had installed the seals backwards! Problem solved.

My first thought was, what else might he have screwed up? But he comes highly recommended by several people, and as the seals are kind of unusually shaped, I can see how it happened. I didn't realize they were in wrong until I removed them.

Thanks for all the input!