front axle rebuild half shaft question

Building up my 90 with a new chassis etc -almost at rolling stage but not quite finished the front axle.

Having just stripped and rebuilt both swivel joints, and new cvs and bearings/seals to front hubs, I am now in the process of what I thought would be the pleasant reassembly - should have been an easy evening's work but ended up a session on one side with a half shaft too short for the circlip (thanks for the threads on the bolt-in-end-and-pull tip - now sorted!).

I have the passenger side done and all seems sweet enough. Before sticking the hub on the driver side, I just noticed by a chance turn of the diff flange that only the passenger side (built end) turns - the driver side half shaft doesn't turn. I thought strange that..... seeing as the passenger side has the full hub and drive flange bolted on and the driver side is just the half shaft and stub axle - I thought if anything this lighter side would have spun at the expense of the higher load of the fully rebuilt end??

If I brace the passenger side then the driver's half shaft does turn although not too freely...do you reckon this is a diff problem or what d'ya think?

Please tell me I dont have to take that passenger side off to lift the diff out an check it over!!

Any advice appreciated.

cheers,
A.

Did you overtighten the hub nut?

I dont have anything bolted to the side that's not turning freely - just the stub axle.

Oh yes, sorry you did say that.

Pull the half shaft out, then stop the other side from turning then turn the diff flange, does it still feel stiff and if so how much force are we talking to get it to turn.

Hi there,
Please can you advise me what to do with the rust on my 1988 defender. I have some rust removal gel and primer..........

Fuzzy-O said:

Hi there,
Please can you advise me what to do with the rust on my 1988 defender. I have some rust removal gel and primer..........

Click to expand...

WTF

I'd suggest you sweep it all into large bin liners and take it to a scrapyard and weigh it in for cash...

Crossed wires with fuzz-o I think!

...anyway. I took the half shaft out like you suggested and the diff flange turns free with no effort.

I put half shaft back in and found it tightened quite a bit but still reasonably low effort to turn. I pulled it out just a few mm and it made a fair difference - I can also turn the half shaft by hand now (couldn't before) and the diff flange rotates freely.

Is it possible I have pushed the half shaft in too far? (and prob wud have had the same issue with no circlip after mounting the hub). I have a bit more confidence tonight that things are ok. Let me know what you think (and btw, thanks for your help on this).

Is the shaft binding where it sits in the back of the hub? Make sure this is all clean, doesn't sound like your issue should be too bad if it's something after the diff and halfshaft related.

Does the shaft have any damage on it, look at the machined smooth section.