Knuckle studs...again

HAHAHAHAHH yeah, i guess we beat that one to death!:dead horse::dead horse::dead horse:

 

Finally, success! New clutches in the Power Lock, new seals all the way through, knuckle studs, & hub studs.
Plus a 2 hole RH knuckle. Already had a 1 piece tie rod, & 11" brakes with drilled drums. Other than converting to discs (not in my budget) I don't think there's much more I can do to this axle...it's about as good as you can get for a D27.

As an aside, the 2 hole knuckle made a tremendous improvement in the steering-greatly reduced effort and bump steer is much less

 

Sounds great!
Still planning on rebuilding the O/D before summer, but I'm hoping that'll be a one day job.

 

So, I have clearance issues at 3 and 9 o clock after an initial test install ( studs not lock-tited in place yet). I'm guessing it's better to grind the head of the cap screw rather than the ball on the axle housing, correct? If I have to, CAN I grind a bit of the ball at 3 and 9?

Going by the pictures in Moses' book, it looks like he ground maybe a 1/4" out of the 3 and 9 positions.

I didn't measure the swing of the knuckles at disassembly in terms steering lock to lock. How do i know when I've got it back to where it needs to be. I can get it close using the steering stop bolts at the rear of the axle but, the opposite direction.......I don't know. Set the axle housing on stands with pinion facing down to the ground and use my angle finder, guessing at where 0* is?

 

I ground a little bit out of the ball on the housing....I don't recall how I determined how much to take.

 

So, this is what I ended up with. Hope it works and I didn't ruin anything. I ground away enough of the ball, at 3 and 9 o clock, to allow the knuckle to swing to the steering stop bolts in one direction. I could kind of see where the knuckle travel stopped in the other direction by the condition of the ball and used that as a gauge as to how much I needed to grind away to allow the knuckle to reach that spot. I took little bits at a time and constantly checked that I wasn't getting past where the seal would be at the opposite side. I think I'll be okay. The right seemed to need more work than the left side. I also worked the 3 and 9 o clock button head screws a bit, removing a bit of the button to help with clearance. Here's the pictures.

 

I vote option 4 then option 3. I don't think a heli-coil will work well here due to the installation tab.

Or epoxy the bolt in

 

#4
Find a 2 hole knuckle (for the other side)while you're at it....

 

You could get one of the mods to do it

Too bad a lot of the pictures are gone....

 

These are the bolts I used I beleave from the McMaster carr link previous.

20190615_202946 by Joe with a jeep, on Flickr

Being a 25 pack I must have 13 or so somewhere in the garage