Rcv axle install help

[SilverBullet]

Well to start this off I originally ordered the revolution chromoly axles but they failed to send me the right ones and were months out on getting new ones from their manufacture. So I went with the rcvs and now I’m struggling with these... can’t win. I can’t get my wheel bearing on the stub axle. Splines look different but rcv said they may be slightly different. Tried hammering the unit bearing on with no luck. I think the stub axle spline is wrong.. help me out. Here’s some pictures.

 

[cjindna]

Curious, have you counted the splines on the RCV and the OE stub you pulled out?

 

[SilverBullet]

Curious, have you counted the splines on the RCV and the OE stub you pulled out?

Yes both are 27 spline.. but if you look at the pictures of both stock vs rcv outer splines you can see there is definitely a difference in the depths of the splines.

 

[cjindna]

on spline count, I agree there appears to be a difference in pitch or possibly tooth thickness but I try not to trust my eyes and instead use a caliper. If you have the ability to take a few precision measurements it will likely be super helpful for you and RCV to resolve.

I’ve installed a few pairs of RCVs in Dana 30/44 and have not run across this issue.

 

[Goatman]

I seem to remember a thread about having to clearance something to get everything to fit right for the RCV axles. Try and get ahold of MrBlaine. He would be your expert on this. (As on most things TJ related)

 

[SilverBullet]

So I’ve gotten in touch with rcv and they have sent me 2 additional sets of outer stubs but they all seem to be the same. Still no luck on getting them on the unit bearing. Stock axle slides on no issue. This can’t be right.