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Old 12-06-2017, 08:17 PM   #11
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Apparently Yukon had a bad batch of axle shafts that caused them to come close to bankruptcy. The axle shafts come with a warranty but only for vehicles that have tires that are up to 32". They did not put a number on the axle shaft. Message is that if you have Yukon axles you might want to contact the company and get more information.

I was told that the spline count is 30. After rebuilding the stock carrier and LSD three times I picked up a FF off of a Superduty E350 and put in a Truetrac along with new gears and bearings. Everything worked fine up until now. If anyone knows where I can get a 30 spline axle shaft 30 for a Superduty E350 I would be interested in looking at it.
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Old 12-06-2017, 08:54 PM   #12
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Dang, SierraHawk what a hassle. Good luck with it.

The axles I pulled out of the D60FF I got out of a salvage yard from a 2001 E350 were 32 spline. I replaced those with 35 spline Dutchman axles as suggested by LetterJ. Seemed like it took more than a couple of days though. Either way, it seems odd that you ended up with 30 spline axles unless it was required by the truetrac? I'd go 35 spline especially considering all the woes to date.
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Old 12-06-2017, 08:59 PM   #13
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I wouldn't take their word for it, physically count the splines yourself, then count them again. There are certainly 30 spline D60FF's out there, but there are also 32 and 35 spline versions. If you are not 100% positive what year it came out of, or if the spline count was changed at the time the lsd was installed, all bets are off. Dutchman can make you 30 spline shafts if that is indeed what you need...

I personally wouldn't waste my time with 30 spline shafts in such a heavy vehicle, while that might be considered reasonably strong in a Jeep, it clearly won't cut it in a fullsize van that sees offroad use. E350 D60FF spindles will accept 35 spline shafts, but you'll still be stuck buying a new carrier to match. If you don't want to deal with it again, that would be the MINIMUM I would consider.
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Old 12-06-2017, 09:33 PM   #14
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Quote:
Originally Posted by SierraHawk View Post
Apparently Yukon had a bad batch of axle shafts that caused them to come close to bankruptcy.
That's the kind of situation that's just bad for everyone involved.

Quote:
The axle shafts come with a warranty but only for vehicles that have tires that are up to 32".
Not terribly surprising, and it's not like a single axle shaft is that big a deal, but more so when you get into the larger situation that you're in now. No fun at all. At least the area you're in is pretty.

I'll +1 on counting the splines yourself. I've really only worked with one mechanic that really understands that these vans have been pieced together from unrelated parts. All the others keep making assumptions about one thing based on another.

As others are suggesting, it's worth considering swapping gears just to get parts to work sooner. I actually had to look this up, since I was confused on why folks were suggesting higher spline count axles for more strength. Higher spline count seems to be directly related to axle diameter. More splines == thicker axle.

Good luck! Also, once you figure out the right axle, consider picking up a spare.
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Old 12-07-2017, 09:22 AM   #15
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SierraHawk thanks for keeping us posted on your axle adventure and I hope for quick resolution for you.

Question for the Axle Gurus.

Am I wrong to conclude that if I was to swap in a full float axle that no mater which donor 1 ton axle I used I would want to configure it for 35 spline shafts? First for availability of parts and secondly for strength?

-Eric
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Old 12-07-2017, 11:56 AM   #16
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SierraHawk thanks for keeping us posted on your axle adventure and I hope for quick resolution for you.

Question for the Axle Gurus.

Am I wrong to conclude that if I was to swap in a full float axle that no mater which donor 1 ton axle I used I would want to configure it for 35 spline shafts? First for availability of parts and secondly for strength?

-Eric
I'm no axle guru but there are more locker options for 35 spline in a D60. Also of note is SMB spec'd the dyntrac prorock60 front axle with 32 spline.

Anyone who has a D60SF on their rig with an ARB locker for example will need to upgrade to 35 spline axles if they do a swap to a full floater. Not sure but the SF has 35 spline and the FF in general was 32 spline.
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