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How to 'gut' a hd truck rear end (remove front diff internals)

leaving enough inside to support axles

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The axle shafts are not required to support the wheel ends, you can just pull the axles out of the ends of the wheel hubs, but you would need to cap it with a cover of some sort to keep the oil in.

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I believe the question was: so that the axles don't flop around with no support where they used to be in the spider gear, huuuumm?

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In most cases where I have seen this done the front chunk is removed and the back chunk is placed in the front drive housing. The through shaft opening has got to be capped off and sealed to complete the front drive. The rear housing does have to have the axle shaft openings capped either by just reinserting the old axle shafts or making plates to cover the axle openings. You also have to plate the opening where the chunk was. I believe Eaton makes a plate to do this but you could also make one out of 1/4" steel so that you can fill the void with oil.

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The rear differential of a DS 404 will not fit into the power divider front housing.

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If it's a Meritor RT-40-145, the rear differential will not fit into the front power divider axle also. The housing is slightly different.

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Hi Jeff, can you share more info about the DS404 rear diff not fitting into the front axle housing? Did you find this out yourself or from somebody else. I'm looking to do this on my W900. By chance do you know if there are any non power divider but locking diffs that will fit into the front housing?

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Stemco makes oil bath covers that will fit in place of the axle shaft.

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The Stemco Part Number for the Meritor Tag Axle is 340-4119. They are about 60-70 bucks a piece. They are very high quality and I highly recommend them to anybody doing this swap.

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Robert the frost plugs came from Napa Auto Parts If your working with a Meritor Housing I'll see if I can find receipt with a part number when I get home. What you do is get a frost plug just a bit bigger than the inside of axle housing so you can drive it in for snug fit.

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No the single drive is just a little shorter had to have drive line 1 inch longer than the one for the power divider unit was

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The driveshaft I am building for this exact same swap on my 2000 Freightliner FLD 120 is 2 7/8" longer than the original shaft to the power divider.

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I just had mine done last week.

Sawed off axles and just use the "nubbins" for end caps.

In addition I know I'm a worrywart so I just had my metal fab shop just make me a template of cover and then fab a flat plate with a threaded fill cap so that I fill axle w/oil up to bearings. I worry about frost plugs leaking and oil running to the bottom and burning up bearings.

Things are doing great so far. Did find that since I was running my 5th wheel so far forward I was taking too much weight off of rear tandem and really rubbering up the tire. Moved kingpin to just behind rear of front tire center and things are much better.

16,000 lb load, 16 stops, 4.6 hours idling and about 24 hours on Proheat. 8.15 MPG. Too small a sample to be sure but I think it's going well. New drive tires too.

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To save a little weight and oil you could weld a plate in the axle tube near the end so you only run a small amount of oil like a trailer hub.

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Rick you don't need to weld anything just use a frost plug to plug it up that's the way I done it works great.

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where do i get a frost plug?

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my other questions are, are the two units the same lenght?

it looks like the front diff with the power divider is longer.

am i goning to have to get a new drive shaft?

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You can have your driveline re-tubed at a drive line shop if it is too short

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I think but not sure I have been trying to look at one of the conway truckload trucks are doing this same they have the same hubs as the drive axle shafts but they have a hubcap like a trailer axle on the rear end. If anybody gets a look at one let me know.

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Robert here's the part number as well as the link to Dorman with full list of all their frost plugs

http://www.dormanproducts.com/catalog/ha...

Part number I used is 555-057

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Mel and I have some decent pictures on this link.

swapping rear differential from 20000lb to 23000lb

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Daniel will be eternally grateful.
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