Front Axle Spline That Goes In Too Tight Fix

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xirdneh
Highest Ranking Member
Posts: 2023
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Front Axle Spline That Goes In Too Tight Fix

Post by xirdneh » Sat Jan 18, 2020 2:11 pm

New axle splines not cut properly and will not insert into transmission.
i used the Dremel tool to remove the top edge so i could speed the process up
coat splines with valve lapping compound
hammer spider gear on and off, over and over until it slides freely
using the puller made life easier but hammer will do
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Love those Tercell 4x4 wagons but they sure suffer from road noise.

The Professor
Highest Ranking Member
Posts: 586
Joined: Wed May 12, 2010 6:38 pm
My tercel:: 1987 Tercel SR5 4WD wagon
Location: Western Washington
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Re: Front Axle Spline That Goes In Too Tight Fix

Post by The Professor » Mon Jan 20, 2020 10:04 am

This should not need to be done. What brand axles are you using?!
1975 Subaru SuperStar wagon
1984 Subaru Turbo-Traction wagon & Turbo-Traction hardtop
1987 Subaru RX 3-door, x2
1987 Subaru RX Type-RA 3-door
1987 Toyota Tercel SR5 wagon
1999 Subaru Forester S
2002 Subaru WRX sedan
2019 Subaru Outback 2.5i Limited

xirdneh
Highest Ranking Member
Posts: 2023
Joined: Thu Aug 04, 2005 11:38 am
My tercel:: 87 tercel 4x4 wagon w/reringed engine, 83 tercel 4x4 wagon w/salvaged engine and 4.1 Diff's
Location: seabeck, washington, USA

Re: Front Axle Spline That Goes In Too Tight Fix

Post by xirdneh » Mon Jan 20, 2020 2:21 pm

i have had this happen on two brands of "new " axles over last 5 years
pictured are cardone
do not remember the other
have done this on at least 14 axles
Love those Tercell 4x4 wagons but they sure suffer from road noise.

teranfirbt
Top Notch Member
Posts: 496
Joined: Mon Mar 30, 2009 12:58 am
My tercel:: '86 SR5 4WD, 5AFE, lifted rear, 195/70/14 tires
Location: Seattle, WA

Re: Front Axle Spline That Goes In Too Tight Fix

Post by teranfirbt » Mon Jan 20, 2020 7:43 pm

I had this happen with a Cardone axle as well, I was able to get it in with sandpaper on the OD for a bit.

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