Rear End Rebuild

[ModelTGal]

Hi folks.

So I've been focused on the disassembly of my 1926 Roadster pickup, and am at the stage now where I am working on rebuilding the driveshaft/tube and rear end. (Or trying to at least)

The axles on mine are shot, one has a shattered key way and the other is deeply worn so I purchased new axles and am now facing the seemingly insurmountable challenge of getting the gears off of the old axles and onto the new axles.

The local machine shops here don't have much if any experience it seems in doing this sort of work. (And they have a 2 week backlog or more)

So wondering what the best approach is to get these gears off of the old axles, and back onto the new ones.

Tried using a 3 ton arbor press, but it doesn't have enough "umph" to move the gears.

I do know from my reading that you have to press the gear down slightly to get the retainer clips out, and then back out off of the end to actually remove the gears and key from the axle.

Whats the trick? Do I need a hydraulic press to do this??? (If so, what size??)

Thank you!!

Jennifer

[TWrenn]

All I know is, when I had my '20 rear end rebuilt the guy almost bent his 20 ton press into a pretzel shape. Some go easy, some need an act of God

[RajoRacer]

If both the old axles are junk, use a cut-off tool or cutting torch to cut off the gears from the axle leaving a short stub to press against - sometimes I've been able to use a 2 lb. hand sledge to hammer the gear down enough to remove the keepers but you will need a hydraulic press to remove the axle stubs - I have a 30 ton AND a cage I built to prevent the axle from bending. A while back some of the new axles didn't have the keyway machined deep enough resulting in a new bent axle and the manufacture of my axle cage - that problem has been remedied.

[Henry K. Lee]

Will have to look but I believe I have some good gears, woodruff keys, and lock ring half moon keepers.

Anything else needed?

Hank

[speedytinc]

I use a 20 ton press. Some axles take all 20. Every rear end I do gets both axles "stretched" lengthened to make up for taper wear.
Put the nut or a nut on to protect the thread. Some axles objectionably flex. I worried about this, but have not seen any with a permanent bend. I do check each axle when done & polish the machined surfaces.
I now have a thick wall tube with a base plate that the axle sits in for the press to minimize the flex.
Its a very simple & easy job. Your shop guy it just lazy & dont want to mess with it. Use a press. A hammer would only destroy.

[ModelTGal]

Wow! Thank you all for the speedy replies!!

-Henry I have good gears (if I can get them off) and new retainer clips and woodruff keys, so I'm good there but thank you for offering!!

So it seems the consensus is I need a 20 ton hydraulic press - and I'll put the nut back onto the threads to protect them from being overly damaged during the process.

On one of the axles the gear actually sides back and forth 40 thousandths, which I find amazing. (Wasn't sure how to write that with numbers, would it be .0040 ??)

Since the old axles are toast I have cut them down so that approximately 1" remains below the gears, for ease of working with them.

For installation onto the new axles it sounds like I need to be concerned about flexing/bending the axles during installation of the gears... Now that's something I don't know how to approach as I don't have access to a machine shop to build a cage to limit the flex, etc.

Any thoughts on how concerned I need to be about that?

Jennifer

[Dan Hatch]

I do it all the time. Let me know if you want help. Dan

[speedytinc]

My press is prone to flexing & parallelograming. A real good press & getting the axle straight may greatly lessen axle flex.
That loose gear? Must be a tight press fit.

[Henry K. Lee]

Pre- heat the gear in an over or low temp torch, freeze the axle over night. Goes on very well!

Hank

[speedytinc]

I'm thinking a trip to the hardware store would make for a simple cage. 1 1/4" x 2' pipe & a floor flange. Taking it to your press guy might ease his fears of bending your axle shafts.

[CudaMan]

When I bought new axle shafts from Chaffin's, I sent them my side gears, woodruf keys, and keepers and they installed them onto the new axles before they shipped them to me.

[ModelTGal]

Yah I wish I had thought of sending my gears/keys/etc., to the vendor I purchased my axles from.

Oh well, live and learn.

I might take Dan up on his offer to help, he's only 2 or 3 hours away and I need to pick up a few other parts from him too.

Its been an amazing experience so far, I know I've only scratched the surface but I've already learned so much!!

Thank you all!!

Jennifer

[Scott_Conger]

Jennifer

Dan is a very nice fellow. I am glad that you are considering accepting his help.

[Henry K. Lee]

Jennifer if Dan does not show appropriate southern hospitality, come this way to Tin-A-See!

LOL,
Hank

[Mark Nunn]

One thing I did to prevent bending new axles was to reinforce them with angle iron before pressing the gears on. I cut 1x1 x 1/8" angles to about 22". I wrapped the axles with tape to protect surfaces and then clamped two pieces of angles onto axles with a few hose clamps. Doing this increased the critical buckling force from about 28,000 pounds to 54,000 pounds. The press I used was 20 tons, which could have buckled an axle without reinforcement.

Good luck.

[RajoRacer]

When "whoever" installs the gear onto the new axle, I use a good rear hub in the press with an axle shim covering the keyway in the hub for the new axle taper to seat tight - the shim assists in the removal - a good smack with a brass hammer against the hub shoulder - pops the new axle right off.

[Henry K. Lee]

Good catch Steve!!!!!