2nd Gen Non-Engine/Transmission broken axle flange bolts

[shorty2500]

does anyone know how i can get two bolts out of my rear hub? they broke off inside the rear hub assembly.



i've been told to heat the hub up with a torch, but i'm afraid of damaging something. i've destroyed too many extractors to laugh anymore.



any advice would be appreciated.

 

[R.ebel]

If the bolt has broke off close to flush try this. Weld a flat washer to the stud (and only the stud) by welding on the inside of the washer. Then weld a nut to the washer. You don't have to weld it real good... just a couple of good tac welds will do. I've used this method twice and it worked for me both times. I think the heat from welding helps to loosen things up without putting an excessive amount of heat into what you are working on. This method was passed on to me buy a heavy equipment field mechanic with 30 + years experience.

 

[illflem]

Trick that's always worked for me is to just touch the top of the bolt with a stick arc welder. The heat is confined to the bolt and it will usually come out with pliers. If it's broken off flush with a broken extractor in it Rebel's method is great.

If all else fails and you are near a big city there are guys with laser stud removers, sounds more expensive than it is, I've found it quite reasonable.

 

[shorty2500]

ok. the bolts came out easily with a little help from the torch. i pulled the hub off and took the bearings out, so there wasn't anything left to damage.



i asked the dealership, and they said they usually heat the bolt up at the head before taking them out and replacing them with new ones. i guess the bolts are intentionally over lock-tite -ed on. they are disposable.



i do have one more question, though. when i tried to put the new hub seal in, the seal was too big. it was for a dana 80, which the dealership said i have, but the one that fits is for a dana 60.



the best explanation that i can come up with is that the rear axle has a dana 80 diff, but the axles and other goodies are different. i've read about this hybrid dana 80 / dana 70 axle that dodge put in these trucks. is this what is going on here?

 

[Andy Redmond]

Shorty



2wd 2500's use the modified Dana 70.



4x4 2500's and 3500 series trucks the modified Dana 80.



A Fed. Mogul Seal/National seal #:



Rear Inner Seal

SPICER 60, 70U, 13" X 2 1/2" BRAKES 417158 yrs 94-00



Rear Inner Seal

SPICER 80, 13" X 3 1/2" BRAKES 455086 yrs 94-00



Good luck,



Andy

 

[CUMINNTSTRKN]

Originally posted by Andy Redmond

Shorty



2wd 2500's use the modified Dana 70.



4x4 2500's and 3500 series trucks the modified Dana 80.





Andy

andy your half right. all 2500's with a manuel get the 80 hybrid, as do all 3500's. all 2500's with the auto get the dana 70.



jim