| 
      
        |  | The 14-Bolt Bible By Bill "BillaVista" AnsellCopyright 2003 - Bill Ansell
 (click any pic to enlarge)
 |  |  
        
          | IntroductionThis article is a compilation of information and and specs relating to the  venerable GM Corporate 14 
              Bolt  full-floating rear axle - also referred to as the 10.5" (after 
              the size of the ring gear in inches) or just simply the "14b" for short.  There are other 14b axles 
              out there - a 9.5" ring gear semi-float for one, and even a  11.5" 
          ring gear full-float version. This article is not about them. |  |  
          | US Military CUCV Manual - 14-Bolt Excerpts |  
        
          |  | A range of US Military trucks over the years have been equipped with the 14-Bolt rear axle, including the   Commercial Utility Cargo Vehicle   or "CUCV". The US Military also produces, free of copyright restrictions, manuals for these vehicles. Normally, the manuals come in large volume sets comprising hundreds of pages covering every aspect of the vehicle. So that you do not have to wade through all this data to find information on the 14-Bolt rear axle, I extracted only the relevant information and compiled it all into a single 14-Bolt Manual in .pdf format. |  
          | Identification, Data, and Specs |  
          |  | The 14bolt is found in a 
              huge number of GM 4x4 pickup trucks and vans, 3/4 and 1 ton, from the 
              70's right through until at least the 2000's. You can find it in: 
              1973-1996 C20, C251973-2000 C30, C351973-2000 G30, G351973-2000 K20, K251973-2000 K30, K351984-1988 CUCV1988-1991.5 V30 As well as a whole lot more 
              cab and chassis trucks, delivery vans, etc. |  
          |  |  
          |  | This is what it 
            looks like in my rock buggy. |  
          |  |  
          |  | It is most easily distinguished 
            by its huge, uniquely shaped diff cover that is, of course, held on with 
            14 bolts. |  
          |  |  
          |  | It is also fairly easily distinguished 
            from other 1 ton full-float rear axles by the removable pinion support, 
            that can be clearly seen just behind the pinion yoke in this picture. |  
          |  |  
          |  | Being a full-float (FF) axle means it has full-floating wheel hubs and axle shafts. I simply love 
              full-float axles, and would never go back to running anything but a FF 
              axle, for the following very good reasons: 
              The axle shaft does not 
                support the weight of the vehicle, but merely transmits torque.Because of the above, FF 
                axle shafts are not subject to bending loads like semi float (SF) axles 
                are and can therefore be made of harder materials making them capable 
                of carrying greater torque loadsIf you should ever break 
                a rear FF axle shaft, you will not loose the wheel too.If you need to change a 
                FF rear axle, it is extremely easy and simple to do.The hubs run big, strong, 
                common, reasonably cheap wheel bearings, races, and seals (14b, Dana 
                60 and Dane 70 bearings, front and rear, are all the same).The wheel bearings are not 
                pressed onto anything. If need be they can be removed and replaced with 
                nothing more than a screwdriver and big hammer. |  
          | Before we delve deeper into 
              the 14bolt, let's just talk about why this is such an awesome axle. It 
              has a number of distinct features / advantages: 
              Gear strength - 10.5" 
                ring gear, 1.750" 30 spline pinion, huge 2 piece carrier made of 
                8620 Heat treated alloy steel, extra pinion bearing support. Shaft strength - 1.5" 30-spline full-floating shafts.Housing strength - massive 
                cast iron center section, 3.25" x 0.5" tubes (not all, varies by year and application).Comes in two widths - 63" 
                and 67" wms-wms, easily converted from one to the other (that axle shafts 
                are common to both, it is the different hubs that account for the different widths, and these are easily interchanged).Removable pinion support, 
                unbolts from the rest of housing, makes for easier gear setup.Diff housing has built-in 
                threaded carrier preload adjusters, makes for easier gear setup.Because the carrier is so 
                large and strong, a "full" Detroit locker fits in the stock 
                housing, and is therefore easy to install without gear setup changes, 
                and is much cheaper than other 1 ton FF lockers.Pinion yokes commonly available 
                for 1350 and 1410 series U-joints.Fairly commonly came stock 
                with 4.10 and 4.56 gears and sometimes factory Detroit Lockers.Cheap and easy to find, 
                buy, and build.Easy to convert to disc 
                brakes.Easy to "shave" 
                for 2" inch gain in ground clearance.Pinion length shorter than 
                other 1 ton full-float rear axles (like the Dana 60 & Dana 70), for improved driveshaft length 
                and angles.Large ID spindles.Shares common spindle-nut threads 
                with Dana 60 front axle, meaning only one style of spindle nut and socket 
                need be used / carried. Of course, there are drawbacks 
              too: 
              Lack of traction aiding 
                differentials - especially spools. Lack of available gearing 
                - only down to 5.13.Lack of aftermarket alloy 
                axle shafts.Carrier break. Most 1-ton 
                FF also have a carrier break though, so it's relative. Uses a crush sleeve to set 
                pinion preload.Relatively low ground clearance in stock form.Heavy in stock trim. Overall, I think they are a 
              superb choice for a heavy duty off-road machine. The following quote from " H8Monday" (a  rock crawling competitor and
              devout throttle-crazy maniac who runs a 14b behind a very healthy 5.0.) 
              sums things up nicely: 
              "One of the best things 
                about the 14-Bolt, other than they are dirt cheap and nearly indestructible, 
                is the cost of building them. It is very common to find them with 4.56 
                gears, and often axle shops and junk yards will have used factory sets. 
                They are very easy to set up, because they have an adjustable backlash. 
                Spare axle shafts are nearly free, and the shafts are the same for the 
                C&C or standard version. Not that spares are usually necessary with 
                a 1.69" axle shaft diameter, (splines are 30). But, the best thing 
                is, because the stock carrier is a monstrous hunk of an assembly, you 
                do not change the carrier [when installing] a Detroit [locker],(its basically a massive lunch 
                box locker). So a Detroit only costs about $325 (and that's if you don't 
                shop around). My disk brake conversion didn't cost over $150 ($40 each 
                for rotors, $40 for loaded calipers, plus about $20 for brake lines). 
                I had about $1000 into my entire 14 build-up, including cost of the 
                axle, gears, locker, disc brakes, and new lug nuts. Not bad for a full 
                floater, rear axle with discs, 4.56 gears and a Detroit." Let's have a closer look at 
              the beast. |  
          |  | This pic is a closer look at the hub and wheel 
              bearing / spindle hardware (with the brake 
              disc or drum removed, looking at it from the back side [inside]). Note that the spindle threads 
              are the same as for Dana 60 front and rear axles and Dana 70 rear axles. 
              This means that all the different styles of spindle nuts (4 slot, 6 slot, hex, 
              rounded hex) and lock washers can all be interchanged. Part numbers for the spindle hardware shown, from left to right are:  
              Spindle flat washer: Dorman 618-048.Spindle nut: Dorman 615-130.Spindle lock washer: Dorman 618-049.Spindle nut: Dorman 615-130. |  
          |  |  
          |  | Watch out for this when you 
              go to remove the wheel hub outer bearing and race. The bearing does not 
              simply fall out of the end of the hub on most FF axles - its OD keeps 
              it captive. Instead, a snap ring in the hub, accessible from the back 
              of the hub (yellow arrows) needs to be removed so the wheel bearing can 
              come out the back. Blue arrows show corrosion, 
              indicating requirement for replacement bearings and races. |  
          |  |  
          |  | The snap ring mentioned above. |  
          |  |  
          |  | Spindle OD is approximately 
            1.985". |  
          |  |  
          |  | Spindle ID is approximately 
            1.540". |  
          |  |  
          |  | Take the cover off, and you 
            discover the massive 2-piece carrier and 10.5" ring gear. |  
          |  |  
          |  | The bearing caps have small 
            integrated locking devices that serve to lock the carrier preload adjusters 
            into place. |  
          |  |  
          |  | Bearing caps and adjuster locking 
            bolts removed. |  
          | These pics are of the carrier removed. 
              Mine is fully welded up making it a huge spool. I have read about some folks 
              just welding the spider / side gears by filing in the valley's between the teeth 
              and then reinstalling them. I personally have never understood this. It's not 
              as if you need to save the carrier, since they are cheap and extremely plentiful. 
              Also, I would think that in this manner, those welds would see quite a bit of 
              shock loading. It's also a real bugger to reassemble the carrier and gears after 
              you have just welded up the teeth and are trying to save the carrier. |  
          |  | With the carrier 
              removed, here's a look inside the diff: 
              Threaded carrier preload 
                adjusters.3/8-NC16 diff-cover bolt 
                hole (14 in total).Extra (third) pinion support 
                bearing.Magnet for attracting and 
                holding metal particles / debris in the gear oil.Area where my 14b has been 
                ground down for clearance.3.25" x 1/2" thick 
                axle tubes. |  
          |  |  
          |  | Close-up of pinion support bearing. The actual proper name for this is the "straddle bearing". |  
          |  |  
          |  | Threaded carrier preload adjuster 
            and 1/2" thick axle tube. |  
          |  |  
          |  | Housing. |  
          |  |  
          |  | The left- and right-hand axle shafts are different lengths.  The Left is the short side at 31-5/8".  The Right is the long 
              side at 37-5/8". |  
          |  |  
          |  | They are a large 30 spline axle. 
            However, the pressure angle on the splines is not the same as other manufacturers 
            (Dana, for example). |  
          |  |  
          |  | Dimensions on the shafts 
              are: 
              Spline Diameter (yellow arrow): 
                1.59""Neckdown" (green 
                arrow): 1.367"Operating diameter (purple 
                arrow): 1.351"Spline length (blue arrow): 
                2.165"Spline engagement (red arrow), short side axle shaft: 1.418"Spline engagement (red arrow), 
                long side axle shaft: 1.569" |  
          |  |  
          |  | Axle diameter by the flange (yellow arrow): 1.458" |  
          | The following pics, courtesy of Benny 
            "Bigger Valves" Langford and Clay "yotacowboy" Moulton,  illustrate an alternate 
            method of retaining the wheel bearings in the 14-Bolt. For the record, the axle shown here is from  an '87 1 ton Chevy V30 (crewcab, 4x4, 350 tbi engine). |  
          |  | It's a very simple 
              setup that consists of one hub nut, one key, and one clip-ring. The nut 
              accepts the regular 6-prong 14-Bolt socket and has 6 square grooves around 
              its inner diameter. These grooves are what you line up with the spindle 
              groove to make the key way, as shown here.  To adjust the bearings,  tighten the hub nut down until the the correct 
              preload is achieved (see the .pdf manual at the start of this article if you are not sure how to do this), and then tighten the nut further until the next groove in the nut lines up with 
              the spindle groove.  |  
          |  |  
          |  | This pic shows the clip-ring and the small rectangular key. |  
          |  |  
          |  | Once the preload is adjusted and the grooves in the nut and spindle are lines up,  simply slide the key 
              in the key way and put on the clip ring. The clip-ring has a curved end 
              that fits in the spindle groove to securely block the key from backing out. 
              The clip is very thin and flimsy which makes it easy to remove with just 
              a screwdriver and allows it to fit snugly around the spindle in the threads. Part numbers for this style spindle hardware are:  
              Hub nut: Dorman 615-132.Key: Dorman 615-140.Clip Ring: Dorman  615-141. |  
          | Dana Catalogue Page on GM 14-Bolt (10.5")
 West Coast Differentials Catalogue Page on the GM 14bolt (10.5")
 GM 14-Bolt Specs(all data for single-rear-wheel (SRW) truck 14-Bolt axle - others may vary). 
              
                
                | 25 - 35 (new 
                    bearings)
                  5-15 (reused bearings) |  
                
                | 5 - 8 thou. |  
                
                | 120 |  
                
                | 135 |  
                
                | Tighten as necessary to obtain 
                  correct preload. |  
                
                | 65 |  
                
                | 35 |  
                
                | 115 |  
                
                | 50 |  
                
                | 20 |  
                
                | 65 |  
                
                | 2.165" total |  
                
                | short side 1.418" |  
                
                | long side 1.569" |  
                
                | 3-3/8" x 0.5" thick (varies depending on year and application). |  
                
                | (1980 1 Ton 4x4, SRW, non Cab 
                  and Chassis) 42.5" x 2.5" |  
                
                | Right 37-5/8" Left 31-5/8"
 |  
                
                | @ splines 1.54", @ neckdown 
                    1.367", operating diameter 1.351" @ flange 1.458"
                  30 splines
 |  
                
                | 8 on 3.523", 1/2" 
                  holes, bolts are 1/2-NC13x1.5" |  
                
                | 7/16 " head, 1.296" 
                  x 5/16-NF24 |  
                
                | Fourteen (14) 3/8-NC16 x 3/4" |  
                
                | Twelve (12) 9/16-NF18 |  
                
                | 1.5" |  
                
                | 3/4" head, 1/2-NC13, approx. 1.5" long |  
                
                | 10.5" |  
                
                | 1.750" x 30 splines |  
                
                | 4.10 / 4.56 |  
                
                | 550 with brake drums 450 without brake drums
 |  
                
                | SRW/DRW 67" C&C DRW 63"
 |  The Different Types of 14-BoltBefore we get into the different types of 14-Bolt axle, a quick review of some truck terminology that will keep popping up is in order. Truck LingoWhen talking about truck, especially with respect t rear axles, we often use the terms SRW, DRW,  C&C, and WMS. Here's what they mean: |  
          |  | SRW stands for "Single Rear Wheel" and refers to a truck that has a single wheel on each end of its rear axle. Your average pickup truck is a SRW truck with a SRW axle. This is my 2007 Chevy Silverado HD2500 "SRW" truck. |  
          |  |  
          |  © GM Company.
 | DRW stands for "Dual Rear Wheel" and refers to a truck that has two wheels on each end of its rear axle. One-ton, heavy-duty pickup trucks are sometimes DRW and are often referred to as "Dually's". This is a 2012 Chevy Silverado HD "DRW" truck. Picture courtesy of and copyright GM Company. |  
          |  |  
          |  © GM Company.
 | C&C stands for "Cab and Chassis" which refers to a truck configuration that is sold without a "box" on the back. It is, literally, just a cab and a chassis (frame), like the one shown here. This is a Chevy C-class C&C truck (so bigger than a one-ton pickup, and it wouldn;t have a 14-Bolt rear axle but the pic clearly illustrates the "C&C" concept. C&C trucks are sold commercially for use as work trucks to customers who need to fit their own specialized bodies such as service trucks, welding trucks, wreckers, and small dump trucks. Picture courtesy of and copyright GM Company. |  
          |  |  
          |  © GM Company.
 | As they are intended for heavy-duty work trucks, C&C trucks almost always also have dual rear wheels. This is Chevy C3500 HD one-ton C&C truck fitted with a small dump box. Picture courtesy of and copyright GM Company. |  
          | WMS stands for "Wheel Mounting Surface". So when we refer to the width of an axle in terms of WMS-WMS we mean the distance between the wheel mounting surfaces (on the hubs). We do this to eliminate the variables of wheel width, wheel offset, and tire width which, if not eliminated, would make for an almost infinite number of possible widths. Back to the 14-Bolt There are many different 14-Bolt 
              axles available, with an almost dizzying array of possible widths, tube OD's, 
              hub types, brakes etc. Fortunately, all are pretty similar, a huge number of 
              parts interchange. *CAUTION* - With this axle, as indeed 
              with all things "axle"  - there are no hard and fast laws - for 
              every "fact" I shall present, I know there's at least one person out 
              there, possibly many, who claim they own or know of exceptions. This is very 
              likely true, and is due to the way in which OEM vehicle construction occurs. This variability and ambiguity is just a fact of life and unfortunately cannot be avoided or completely resolved. What follows is what I believe to 
              be true, or the most correct, information based on the research I have done 
              and the letters I have received from what I judge to be the most reputable sources. 
              Use the data with caution - "your mileage may vary" as they saying goes. 14-Bolts can be broken down into 
              4 broad groups. There is also at least one year break that brings minor changes, 
              but this is in fact far less significant than the "type" of 14-Bolt 
              axle in question. Once again - this article is concerned 
              only with GM 14-Bolt full-float rear drive axles. With that said, the following 
              table attempts to capture the data. 
              
              
                | SRW
 | 67.5" | 3-3/8" / 0.5" | Single rear wheel trucks | Type A | Type 1 |  
                | DRW 
 | 72" | 3.5" / 0.5" | Dual rear wheel trucks | Type B | Type 2 |  
                | C&C
 | 63.5" | 3.5" / 0.5" | Cab and chassis trucks | Type B | Type 1 |  
                | Van | 70" | ?? | G30 and G35 vans | Type A | Type 3 |  * Note that these names (or designations) are of my own invention. They are not the official designations used by the manufacturer. Unfortunately, I do not know what the official designations are, or I wold have used them. So, don't call up your local junkyard and ask if they have a 14-Bolt with "Type B" hubs and "Type 1" shafts - they will look at you funny (yes, even over the phone!) I have simply invented and used these terms to help illustrate the differences and similarities between the different axle types that are out there. Notes: 
              The width of the housings and the length of the shafts  used in the SRW and C&C 
                axles are the same. The reason they are different widths WMS-WMS is because of the difference in the hubs used (see below for different hub types). The housings are actually identical except for the location 
                of the backing plate flange (except axle tube OD and thickness may vary slightly with year and application). The brake drums & hubs are different, but the backing plates, 
                brake shoes, and wheel cylinders are the same. The SRW and 
                Van axles use the same hubs.The C&C and DRW axles use the same hubs. Though different, the Type A (SRW/Van) hubs and the Type B (C&C/DRW) hubs can be interchanged. Doing so will result in a  change to the axle's WMS-WMS as follows:
                
                  Swapping Type A hubs onto where Type B hubs used to be will cause an increase in axle width WMS-WMS.Swapping Type B hubs onto where Type A hubs used to be will cause a reduction in axle width WMS-WMS.See section below for pics of the different types of hubs to see why this is so. SRW and C&C 
                axle shafts are the same Van, DRW, 
                and SRW/C&C axle shafts are all different lengths as follows (long (right) 
                side / short ( left) side):
                
                  Type 1 - SRW/C&C 
                    - 37-5/8" / 31-5/8"Type 2 - DRW 
                    - ??Type 3 - Van 
                    - 39-3/8" / 33-3/8"If it helps, you can think of the C&C axle as a hybrid of the SRW and DRW axles. It uses the housing and shafts of the SRW axle fitted with the hubs of the DRW axle. This accounts for why it is the narrowest axle measured WMS-WMS (which in turn is why it is often highly sought-after for swapping into smaller 4x4s like Jeeps and buggies.C&C and DRW 
                brakes are the same.In all cases one 
                side axle-shaft is shorter than the other and pinions are centered.1350 appears to 
                be the only available stock pinion yoke, but aftermarket 1410 yokes are available (see the XXX article for details).1-ton pickup trucks feature 
                40.5" leaf spring perch spacing - whether   SRW or DRW.C&C axles feature 36" leaf spring perch spacing. 3/4-ton leaf spring perch spacing is 42.5" spacing. \Wheel studs went 
                metric for the 88-up C/K trucks, and 96-up vansFront 60 and rear 
                14b spindles have the same bearing spacing and same bearing journal sizes. 
                The seal journal diameter is different Type A and Type B HubsThe following pics, courtesy of Brawler, illustrate the differences between the Type A and Type B hubs. |  
          |  | Type A 
              hub on left. Type B hub on right. |  
          |  |  
          |  | Type A (SRW / 
              Van) 14-Bolt hub. The flat, machined flange you see here (through which the wheel studs are poking) is the wheel mounting surface or WMS we keep referring too. Notice how short the central part of the hub that sticks out past the WMS is. |  
          |  |  
          |  | Type B (C&C / DRW) 14-Bolt 
              hub. Notice how much longer the central part of the hub that sticks out past the WMS is, compared to the Type A hub, above. |  
          |  |  
          |  | Type A 
              hub on left. Type B hub on right. This picture is taken with the two hubs sitting on the bench simulating the position they would each be in when mounted on the spindle. You can clearly see the higher height of the WMS of the Type A 
              hub on the left that translates into the wider WMS-WMS width of an axle fitted with Type A hubs compared to one fitted with Type B hubs. |  
          | Different YearsThe year split is '72-88 (so-called "first design") and 89+ (so-called "second-design). 
              Of course, there may be variations. Differences between these years are noted 
              below. Where the difference is known only to apply to certain "types", 
              I shall indicate this.  
              Second design axles have more 
                fins on the center section.First design axles 1984 and earlier 
                use a different pinion straddle bearing than 1985 and later.Second design SRW axles in 1-ton 
                pickup trucks and 3/4 ton Suburbans changed to allow for a slide-off drum 
                (drum can be removed without pressing out the wheel studs). The backside of 
                these hubs is not machined flat to accept a rotor, for example. The hub flange 
                is also further inboard to allow for the thickness of the drum. When working on a 14-Bolt axle, the biggest difference between the first and second design to be aware of is the different bearings used in the diff. The wheel bearings, pinion seal, and front pinion bearing are common to both first- and second-design axles. The first-design axle uses a different rear pinion bearing than the second-design axle. And the really confusing part is that the first-design and second-design axles use the same pinion straddle bearing EXCEPT for the 1984-1985 first-design axles which use a different straddle bearing from all the rest. Perhaps the best way to explain this is to simply list the part numbers. The seal & bearing numbers 
            are*: 
              Pinion Seal (1973-1999): 
              21955Front Pinion Bearing, 
                Cone, (1973-1999): M802048Front Pinion Bearing, 
                Cup, (1973-1999): M802011Rear Pinion Bearing, 
                Cone, (1973-1988): HM803149, (1988-1999): HM903249Rear Pinion Bearing, 
                Cup, (1973-1988): HM803110, (1988-1999): HM903210Pinion Straddle 
                Bearing, (1973-1984 & 1986-1999): R1581-TV Pinion Straddle 
                Bearing, (1984-1985): DC57524 * Cone = the roller 
            or bearing, Cup = the race. |  
          |  | This picture illustrates the heavily ribbed centre section of the second design 14-Bolt 
            housing (ignore the red arrow). |  
          | 14-Bolt Wheel StudsOne of the most popular modifications to any 14-Bolt axle used in an offroad truck is to remove the huge, heavy drum brakes and swap to disc brakes. I wrote a compete article on this process which you can read for detailed info. One thing though, is that when you swap from drums to discs, the wheel studs are usually no longer long enough because they have to pass through the disc and the hub (that's how the disc is held to the hub). Over the years there has been much discussion and experimentation with using different wheel studs, with different folks reporting different levels of satisfaction with different options. As far as I know there has never been a universally accepted one perfect solution, but the following data I consider quite reliable and should at least allow you to narrow down some choices with which to experiment to achieve a level of satisfaction you are comfortable with.             How to Cure the 14-Bolt of it's Achilles Heel weak link!The  mighty 14-Bolt does have 1 terrible weak link - an Achilles Heel.  
              It's the crappy, lousy design, weak, expensive and hard to find straps for holding 
          the U-joint in the pinion yoke. |  
          |  | The proper straps are a pain to find. No parts store I 
              have ever tried, from NAPA to Car Quest ever has them. That leaves only the GM dealership, where the strap (GM p/n: 3920486) 
              will set you back $3 EACH! and the bolts (GM p/n: 458300 or 14018700) 
              another $2 EACH.  |  
          |  |  
          |  | As for all the local and big chain parts stores - they will all gladly 
              sell you a "strap kit" for a "1-ton GM rear axle" 
              or "GM 10.5" rear end" or a "14-Bolt full floater" 
              or a "1980 Chevy K30 1 ton 4x4 " or whatever else you have to 
              say to them to get one - but, in my experience (NAPA, Car Quest, Canadian 
              Tire, and a couple of local independents) they are all WRONG, and it won't 
              fit at all. The top strap is the one the parts stores will sell you, the bottom the 
              GM part. |  
          |  |  
          |  | In any case - the stock straps are weak and badly designed - very soon 
            they end up looking like this. |  
          |  |  
          |  | Complete junk!! |  
          | Fortunately - there is a solution - and a very cool one at that - read all 
              about it  - the High Angle Driveline 
              1410 Pinion Yoke kit Shaving the 14-BoltThe only real disadvantage to the 
              14b is the huge size of the differential, and subsequent scarcity of ground 
              clearance. I must admit, in stock form, they do tend to hang a little low and 
              get hung up on stuff. Most users will "shave" them. This can range 
              from simply smoothing out the bottom with a hand grinder, to cutting a big chunk 
              out of the bottom of the diff housing and machining down the diameter of the 
              ring gear. The following pics illustrate the 
              nicest case of the later, more extreme, shaving job that I have come across. 
          It is the work of  Phil Jensen, from Ottawa, Canada. |  
          |  | The diff before 
            the shave. |  
          |  |  
          |  | The piece cut from the diff 
            housing. Phil used an abrasive wheel/blade in a circular saw to start, and 
            finished with a reciprocating saw. Starett blades are reportedly good for 
            this. |  
          |  |  
          |  | After the cut of the housing, 
            this is the carrier back in place, before it was machined down. It was then 
            removed and approx. 1/4" machined from the OD of the ring gear. This 
            did not effect the performance or durability of the gear set at all. |  
          |  |  
          |  | The 1/2" thick mild steel 
            plate that was TIG welded to the housing. |  
          |  |  
          |  | The plate welded in place |  
          |  |  
          |  | The gears machined and re-installed Just over 2" of clearance 
              was gained. That's the same (at the diff) as going from 35" to 39" 
              tires!! |  
          | Originally, Phil made a quick 
              cover by altering a stock cover. It didn't last well enough for his liking, 
              so in the end he constructed a complete custom cover from 3/8" plate 
              steel, which has reportedly held up very well. Unfortunately, I have no 
              pictures of the later cover, but here are some of the original.      
 From the research I have done (I 
              have no personal practical experience) the methods that have been used successfully 
              for trimming the OD of a ring gear for a radical shave job are: 
              Abrasive grinderDiamond-tip on latheCeramic inserts on latheWire EDM I believe the preferred method is 
              the wire EDM. Here's what engineersedge.com has to say about EDM. 
              
                | EDM is one           of the most accurate manufacturing processes available for creating complex           or simple shapes and geometries. EDM works by eroding material in the           path of electrical discharges that form an arc between an electrode tool           and the work piece.  EDM manufacturing is quite affordable and a           very desirable manufacturing process when low counts or high accuracy           is required.  Turn around time can be fast and depends on manufacturer           back log. The EDM system consists           of a shaped tool, an electrode, and the part. The part is connected to           a power supply. To create a potential difference between the work piece           and tool, the work piece is immersed in a dielectric (electrically nonconducting)           fluid which is circulated to flush away debris. The cutting pattern is           usually CNC controlled.  Many EDM machine electrodes can rotate about           two-three axis allowing for cutting of internal cavities. This makes EDM           a highly capable manufacturing process. EDM comes in two basic           types: wire and probe (sinker). Wire EDM is used primarily for shapes           cut out of a flat sheet or plate. With a wire EDM machine, if a hole needs           to be created, an initial hole must first be drilled in the material.           Then the wire can be fed through the hole to complete the machining. Sinker           (probe) EDMs are generally used for complex geometries where "line of           sight" is not thru/straight or very small pieces where conventional milling           is not practical or very difficult due to the hardness of the material-such           as cast and heat treated tooling. Probe EDM can cut a hole into the part           without having a hole pre-drilled for the electrode. Design Considerations 
                    Relax the surface-finish             for the part, if feasible. This allows the manufacturer to produce the             part with fewer passes, at a higher current level and a higher metal-removal             rate.           Design the part such             that the amount of stock removed by EDM is relatively small. Use traditional             machining techniques to remove the bulk of the stock with the finishing             operations performed by EDM. This significantly reduces the amount of             time and cost for each part.           The EDM manufacturer             should consider fixturing such that several parts can be stacked and             machined simultaneously or a single part can have several EDM operations             performed simultaneously. When existing holes             are to be enlarged or reshaped by EDM, through holes are preferred to             blind holes as they permit easier flow of dielectric fluid past the             area being machined  Dimensional Accuracy (+/-           0.0005 inches per inch)Feature Profile accuracy of .0003 is obtainable with cutting path
 Features to feature true position of .002 is reasonable and down to .001 is possible when geometry requires           removal and reattachment of wire.
 
 Surface           Finish (micro inches) Features created by EDM have an "orange peal"           appearance.
 32 RMS is achievable, 64 or higher RMS is typical. Wall Thickness
 Min Wall Thickness (inches): 0.01 (over a 5" inch span)
 DepthSignificant depths can be obtained with wire EDM, probe EDM does have           depth and access limitations dependant on machine capabilities.            Consult with EDM manufacturer for specifics.
 |    14-Bolt Part Numbers from the On-line Listing at DTS 
              
                                 
                  | Product           Name Description | Manufacturer |  
                  | GM           3920486GM           10.5 YOKE STRAPS |  |  
                  | GM26004800GM           10.5 PINION SUPPORT 91 & NEWER |  |  
                  | EAED19689-1GM           10.50 4.10 NUMERICALLY LOWER POSI CARRIER |  |  
                  | EAED19610-1GM           10.5 4.56 NUMERICALLY HIGHER POSI CARRIER |  |  
                  | DTS327721-GGM           10.5 3.73 RATIO (O.E.M) |  |  
                  | DTS26026100-GGM           10.5 4.56 RATIO (O.E.M) |  |  
                  | DTS26016819-GGM           10.5 4.88 RATIO (O.E.M) |  |  
                  | AAM           GM10.5I-33GM           10.5 SPYDER GEAR KIT (OPEN) |  |  
                  | AAM           6258340GM           10.5 OPEN CARRIER 4.56 NUMERICALLY HIGHER |  |  
                  | AAM           6258336GM           10.5 OPEN CARRIER 4.10 NUMERICALLY LOWER |  |  
                  | AAM           26055283GM           10.5 5.13 RATIO (O.E.M) |  |  
                  | AAM           26055280GM           10.5 3.42 RATIO (O.E.M) |  |  
                  | AAM           26054996GM           10.5 3.73 RATIO (O.E.M) |  |  
                  | AAM           26054993GM           10.5 4.10 RATIO (O.E.M) |  |  
                  | AAM           26054990GM           10.5 4.56 RATIO (O.E.M) |  |  
                  | DTS471871GM           10.50 3.73 RATIO | DTS |  
                  | PGGM14/375GM           10.50 3.75 RATIO | PRECISION           GEAR |  
                  | DTS471872GM           10.50 4.10 RATIO | DTS |  
                  | DTS14012704GM           10.50 3.42 RATIO-GENIUNE GM | DTS |  
                  | SPGM-14-105-373GM           10.50 3.73 RATIO | SPICER |  
                  | DTS327721-GGM           10.50 3.73 RATIO O.E.M STYLE | DTS |  
                  | PTX95-0705-3000GM           10.50 30 SPLINE FITS OPEN DIFFERENTIAL | POWER           TRAXX |  
                  | MGGM10.5-373GM           10.50 3.73 RATIO | MOTIVE           GEAR |  
                  | LR1955GM           10.5-2 PIECE CASE | LOC           RITE |  
                  | MGGM10.5-513XGM           10.50 5.13 RATIO THICK GEAR 4.10 &DN CARRIER | MOTIVE           GEAR |  
                  | MG3663696GM           10.50 CROSSHAFT | MOTIVE           GEAR |  
                  | GM26020811GM           10.50 YOKE | GM |  
                  | PGGM14/513TGM           10.50 5.13 RATIO THICK | PRECISION           GEAR |  
                  | IK83-1023GM           10.50 BEARING KIT | DTS |  
                  | IKGM14SKGM           10.50 PINION SHIM KIT PINION SHIMS | DTS |  
                  | DTS1551438-GGM           10.50 5.13 RATIO O.E.M STYLE | DTS |  
                  | DTS6258336-GGM           10.50 EMPTY OPEN CARRIER 4.10 & DOWN | DTS |  
                  | DTS6258340-GGM           10.50 CASE 4.56 & UP EMPTY MUST USE (GM 331421) RING BOLT | DTS |  
                  | GM26067040GM           10.50 COVER | GM |  
                  | PGGM14/456GM           10.50 4.56 RATIO | PRECISION           GEAR |  
                  | IK83-2023GM           10.50 INST KIT NO BEARINGS | DTS |  
                  | IK83-1023AGM           10.50 BEARING KIT 91 & UP DIFF PINION BEARINGS | DTS |  
                  | GM15994582GM           10.50 PINION NUT | GM |  
                  | DTS6258336GM           10.50 CARRIER EMPTY OPEN | DTS |  
                  | DTS471873GM           10.50 4.56 RATIO | DTS |  
                  | MGGM10.5-410GM           10.50 4.10 RATIO | MOTIVE           GEAR |  
                  | PGGM14/410GM           10.50 4.10 RATIO | PRECISION           GEAR |  
                  | SPGM-14-105-410GM           10.50 4.10 RATIO | SPICER |  
                  | DTS26029468-GGM           10.50 4.10 RATIO O.E.M STYLE | DTS |  
                  | DTS26026100-GGM           10.50 4.56 RATIO O.E.M STYLE | DTS |  
                  | MGGM10.5-488XGM           10.50 4.88 THICK | MOTIVE           GEAR |  
                  | MGGM10.5-456GM           10.50 4.56 RATIO | MOTIVE           GEAR |  
                  | SPGM-14-105-456GM           10.50 4.56 RATIO | SPICER |  
                  | PGGM14/456TGM           10.50 4.56 RATIO THICK | PRECISION           GEAR |  
                  | MGGM10.5-456XGM           10.50 4.56 RATIO-THICK | MOTIVE           GEAR |  
                  | DTS26016819-GGM           10.50 4.88 RATIO O.E.M STYLE | DTS |  
                  | PGGM14/488TGM           10.50 4.88 RATIO THICK | PRECISION           GEAR |  
                  | GM331421GM           10.50 RING GEAR BOLTS 4.56 | GM |  
                  | MGGM14BIGM           10.50 SPYDER KIT | MOTIVE           GEAR |  
                  | GM331422GM           10.50 RING GEAR BOLTS '4.10 & DOWN | GM |  14-Bolt Wheel bearings and Seals
              
                | 
                    
                        
                        | Hub                 Seal |    
                        | Interchange                 Number | Mfr |  
                        | 14116 | FELTPR |  
                        | 15527652 | GM |  
                        | 2081 | ABI |  
                        | 2081 | TIMKEN |  
                        | 2081 | DELCO |  
                        | 2081 | L&S |  
                        | 211587937 | GARLOK |  
                        | 2620286 | DELCO |  
                        | 28426 | C-R |  
                        | 29112 | DELCO |  
                        | 3680994 | GM |  
                        | 3686563 | GM |  
                        | 37222 | SPICER |  
                        | 3742583 | GM |  
                        | 3743202 | GM |  
                        | 3828916 | GM |  
                        | 3883386 | GM |  
                        | 3909063 | STEMCO |  
                        | 3929063 | STEMCO |  
                        | 3974847 | GM |  
                        | 41X10836A | DEERE |  
                        | 455511 | NATION |  
                        | 46203 | TROSTL |  
                        | 469694 | GM |  
                        | 48287 | DANA |  
                        | 49552 | VICTOR |  
                        | 49552SF | VICTOR |  
                        | 51X7937 | GARLOK |  
                        | 60964 | VICTOR |  
                        | 63X7937 | GARLOK |  
                        | 84503 | FITZGE |  
                        | A215F964 | R-S |  
                        | A56401S | L&S |  
                        | A56401S | TROSTL |  
                        | BH1290E | NOK |  
                        | BH1290E1 | NOK |  
                        | GS1360 | AURORA |  
                        | T2586 | CHRYSL |  
                        | T28425 | CHRYSL |  
                        | T55511 | TROSTL |  | 
                    
                      | Inner               cup |  
                      | Interchange Number | Mfr |  
                      | 0009813580KZ | M-BENZ |  
                      | 0009814581KZ | M-BENZ |  
                      | 053146 | RIV |  
                      | 105497H | IHC |  
                      | 10578 | A-C |  
                      | 107845A | WHITE |  
                      | 10A7292 | WHITE |  
                      | 111E050032 | AM |  
                      | 111E0500321 | AM |  
                      | 1331442400 | ARAMCO |  
                      | 142223 | GM |  
                      | 149505 | MACK |  
                      | 150805 | JEFREY |  
                      | 167717C1 | IHC |  
                      | 195521M1 | MASSEY |  
                      | 195525M1 | MASSEY |  
                      | 196068M1 | MASSEY |  
                      | 1AE0334 | WHITE |  
                      | 20641 | EATON |  
                      | 207234H1 | IHC |  
                      | 212037 | A-C |  
                      | 2150007 | GOODMN |  
                      | 2150007 | WABCO |  
                      | 3010578 | A-C |  
                      | 30105787 | A-C |  
                      | 313037 | AUSTIN |  
                      | 354T5 | WHITE |  
                      | 382A | NTN |  
                      | 382A | TIMKEN |  
                      | 384350R1 | IHC |  
                      | 388533R1 | IHC |  
                      | 392689R1 | IHC |  
                      | 3950457 | GOODMN |  
                      | 45733 | HYSTER |  
                      | 471489 | WABCO |  
                      | 49029 | NEWHOL |  
                      | 4T382A | NTN |  
                      | 516149E | WHITE |  
                      | 520013 | GEHL |  
                      | 545905 | EATON |  | 
                    
                      | Inner               Cone |  
                      | Interchange               Number | Mfr |  
                      | 10X15157 | WHITE |  
                      | 1331445600 | ARAMCO |  
                      | 181267 | WABCO |  
                      | 206087M1 | MASSEY |  
                      | 218285 | A-C |  
                      | 2182855 | A-C |  
                      | 243146 | RIV |  
                      | 319014 | AUSTIN |  
                      | 327195R91 | IHC |  
                      | 387AS | NTN |  
                      | 387AS | TIMKEN |  
                      | 49030 | NEWHOL |  
                      | 49X50209A | DEERE |  
                      | 4T387AS | NTN |  
                      | 565906 | SPICER |  
                      | 613862C91 | IHC |  
                      | 826926C91 | IHC |  
                      | 9436882 | GM |  
                      | 9500172 | JOY |  
                      | 95X387AS | JOY |  
                      | A629826 | GERLIN |  
                      | C5NNA767A | FORD |  
                      | C7TZ1244A | FORD |  
                      | F387AS | SEAL-P |  
                      | JD8147 | DEERE |  | 
                      
                      | Outer               Cup |    
                      | Interchange               Number | Mfr |  
                      | 1331928200 | ARAMCO |  
                      | 287066 | NEWHOL |  
                      | 2953549 | CHRYSL |  
                      | 2955374 | CHRYSL |  
                      | 364462C1 | IHC |  
                      | 431667C1 | IHC |  
                      | 4TLM104911A | NTN |  
                      | 565918 | SPICER |  
                      | 7451813 | GM |  
                      | 8128842 | AMC |  
                      | 9428539 | GM |  
                      | C7TA1239A | FORD |  
                      | C7TZ1239A | FORD |  
                      | LM104911 | NTN |  
                      | LM104911 | TIMKEN |  | 
                      
                      | Outer               cone |    
                      | Interchange               Number | Mfr |  
                      | 1331928500 | ARAMCO |  
                      | 2825729 | CHRYSL |  
                      | 2852729 | CHRYSL |  
                      | 2852729 | GM |  
                      | 2953550 | CHRYSL |  
                      | 364463C91 | IHC |  
                      | 431668C91 | IHC |  
                      | 4TLM104949 | NTN |  
                      | 5357401 | AMC |  
                      | 565905 | SPICER |  
                      | 591651C91 | IHC |  
                      | 7451814 | GM |  
                      | 8128841 | AMC |  
                      | 929742 | A-C |  
                      | 9428909 | GM |  
                      | C7TA1240A | FORD |  
                      | C7TZ1240A | FORD |  
                      | FLM104949 | SEAL-P |  
                      | J5357401 | CHRYSL |  
                      | JD9070 | DEERE |  
                      | LM104949 | NTN |  
                      | LM104949 | TIMKEN |  
                      | LM104949JX2 | NTN |  |  |  |