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  #1  
Old 04-01-2012, 04:52 PM
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Default 1500 front axle question - wrong number of splines??

I bought this 96 1500 5.9 4x4 a month or so ago knowing the drivers front axle shaft was junk and would need replacing. I figured with one side trashed and I'd have all the tools out, I'd just bit the bullet and do the other side as well instead of having something happen 30 miles in the woods in a thunderstorm and a dead cell phone battery. Yes, Mr Murphy and I have been around the laws a few times...

Ok. So ended up ordering both sides from rockauto.com. Decent shipping and price, good turnaround time. Now on the truck I bought, the left side axle shaft is gone, all that is left is the broken stub attached to the hub. The right side one, the joint is shot. I figured in for a penny, in for a pound so I ordered both sides for a 1500 with a Dana 44. Got around to doing the job today, pulled the right hub (came off nice and cleanly too, last one I did snapped the bolts). Pulled the axle shaft. Slide the new one in. Didn't feel right, like it wasn't even trying to engage the splines so i pulled it out and looked at it closer. CRAP. I have a 15 spline old unit, the new one is 30. It's a lot thicker of a shaft as well (the original one) as you can see in the photo below. The part that snugs into the hub is different as well. Now, on this side I can return the shaft and just replace the joint instead. On the driver's side, there is no inner part of the shaft and the stub is junk. What do I order? Rockauto only gave me one choice. So does partsgeeks. And Advanced Auto. And Autozone. I think this is going to screw me up when I have to replace hubs in the future as well... HELP???
Possibly a 2500 axle? The build sheet says 195mm...

Oh, and anyone need both sides for a 30 spline? I'll sell mine cheap
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Last edited by SnoopyIsMyHero; 04-01-2012 at 06:31 PM.
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  #2  
Old 04-01-2012, 07:16 PM
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SnoopyIsMyHero SnoopyIsMyHero is offline
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Ok, looking around it appears that the front axle is a Dana 60, not a 44. That sound right?
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Old 04-01-2012, 08:28 PM
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Actually they're both Spicers.

The smaller one with the 30 spline shaft is out of a 1500 and it's a Spicer 44.

The Larger one is out of a 2500-3500 Spicer 60.

If you're looking to buy a used one and just replace the univeral joints. I have a spare right side, or you can try Car-Part.com

Last edited by Warlock III; 04-01-2012 at 08:30 PM.
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Old 04-01-2012, 09:03 PM
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Thanks! All the part places say Dana which is why I said that, glad to know the truth.
My right one is good (besides the joint, which I've already pressed out and will pick one up this week) but thanks for the offer, the left one is MIA. Now that I know what I'm looking for, the search should be easier. I'm going to troll junkyards this week and try that site you posted.
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Old 04-01-2012, 09:31 PM
Warlock III Warlock III is offline
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The site is a parts locator and checks junk yard inventories if they have them entered in their computer system. It might save you some calling/driving.
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Old 04-01-2012, 10:03 PM
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Dana/Spicer is a company
http://www.spicerparts.com/axle/automotive.asp

Here is some information about your front differential
http://quad4x4.com/Dodge1500Dana44front1994-2001.html
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Old 04-01-2012, 11:50 PM
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They may have sent you the wrong ones, for the dana 44 it should be a dorman #630411 26 1/2 in long and 15 spline. The left side is dorman #630412 27 in long and 29 spline.
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Old 04-02-2012, 10:44 PM
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This is what I ordered:

Dorman Axle Shaft - Front Right
In Stock
Part Number: 1966-07089188
Notes: Axle Shaft -- Front Right; 4WD; Dana 44 Axle;
Position: Front RightFront: 195MM

Dorman Axle Shaft - Front Left
In Stock
Part Number: 1966-07080497
Notes: Axle Shaft -- Front Left; 4WD; Dana 44 Axle;
Position: Front Left

They both match visually what is shown in the parts catalog. The pics below is what I pulled from the right side, the last one being it next to the new one sent for the right side. There is a definite difference in diameter, splines and outer stub configuration, there's no way it would fit in the hub. The new part looks just like the one in my son's 99 Jeep GC 5.9. The one I took out of it looks like the pics I've seen from a series 60 front end. Since I don't have a left one at all, I'm kinda confused on where to go from here. This being said, I have not tried to put the left side in, I saw the right side didn't match at all and the left looks a lot like the right, just shorter, so I stopped and reached out for help.






Build sheet:
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*P1 Premium Cloth 40/20/40 Bench Seat
ADAP Light Group
AGG Sport Group
AJKP Convenience Group
AJPP Power Convenience Group
APAS Monotone Paint
ASPP SLT Decor Group
BAUS 117 Amp Alternator
BCES 600 Amp Maintenance Free Battery
BGJS Pwr Disc/Drum Rr Anti-Lock Brakes
BKAS 11x2 Rear Drum Brakes
CBEP 40/20/40 Split Bench Seat
CGTS Driver Air Bag Only
CHEP Deluxe Headliner
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CSPS Passenger Assist Handle
CSRP Passenger Assist Handles
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DGB All 4-Speed Automatic Transmissions
DGTS 4-Spd. Automatic 46RE Transmission
DHAS Lock-Up Torque Converter
DHKS Shift-on-the-Fly,231HD Transfer Case
DJCS 195MM Front Axle
DMDS 3.55 Rear Axle Ratio
DRBS Corporate 9.25 LD Rear Axle

EAAC All Engines
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Last edited by SnoopyIsMyHero; 04-02-2012 at 10:53 PM.
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Old 04-02-2012, 11:09 PM
Warlock III Warlock III is offline
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Default

Okay, was there a tag on the differential cover?

The other thing to check is the casting on the Differential tab. Should be the part that's triangle shaped and horizontal to the ground. Should have a 44 on it. The one you received is the right one for the truck...but since you got it used I'd have to say it was changed...OR and this is the kicker...

The axle you're showing me looks like it's out of a '94/'95. Check the production date on your truck.
I have a feeling it was made in '95 for '96. If the yolk is 3 1/4 wide (picture is hard to tell) call the parts store and have them look it up for a '95...then cross check the part number with the one you have.

That's where the problem is. Guaranteed. If I turn out to be right, you can thank me by giving me a reputation point. Upper right hand of this post and looks like a justice scale. I will be checking back because I know I'm right.

What confuses me is the corporate rear axle. I've seen quite a few trucks where the front have been changed. Or the factory continued to use old stock until the new ones came in and is probably what you are experiencing.

UPDATE!! I had a thought and just went outside... Guess what? My spare axle, you guessed it, it's exactly like the one with the larger splines you have pictured. And I have a '95.

P.S. Nice shoes



Thank you, thank you...don't applause, just throw money.

Last edited by Warlock III; 04-02-2012 at 11:35 PM.
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  #10  
Old 04-02-2012, 11:17 PM
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SnoopyIsMyHero SnoopyIsMyHero is offline
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Thanks! I looked for a tag on the diff cover, no joy. The cover has been off because there's RTV splooged all over the edges so probably was not put back on but I'll check for the casting tab in the morning in the light. I just talked to the PO and the rear is not original to the truck, it blew last year and he replaced it with one out of a 2500 but didn't touch the front. Need to replace the rear u-joint soon, guess I'll have an adventure in parts hunting then too. He did say it was used as a plow truck by the guy before him so maybe the front was replaced along the way...who knows?? Thank you so much for the input. I'll update when I've got it back together
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