DSS pro axle hitting knuckle...
 

So i went to evasive motorsports to get my DSS pro axles installed, and they hit the knuckle before seating all the way. I talked to driveshaft shop and they said every once in a while they see this issue, they dont know why there is a slight difference in knuckles sometimes. They said all i have to do is clearance the knuckle where the axle touches. What is everyones thoughts on this. The spot where it touches looks like it would be ok to grind out a bit. I was also thinking of just buying used knuckles to grind and fit to make sure it worked. I just dont want to compromise the knuckles integrity.

http://i188.photobucket.com/albums/z...479FE43D28.jpg

Woah didn't know we had different knuckles from model to model! I have their 600hp rated axles but luckily I didn't run into any problems.

From the looks of though it doesn't look like much needs to be ground off. If anything I have found many spare knuckles on ebay.

Visit my build on Instagram @kawallito

Can you shim between the spindle and the wheel bearing? I'd do that first if possible.

If you do have to grind the carrier a little just make sure you have no sharp corners. Get it nice & round so you avoid stress concentrations.

I saw this post on FB too, but didn't comment there.

I have the 600 HP units and I didn't have this issue. There are 2 different sizes for the joints on the ones that I have, and I installed them with the larger joints on the inside at the diff. Do these have larger joints on both sides?

There should not be much of a load there if I'm thinking about it correctly. Castings can move quite a bit, I would have expected more clearance but perhaps they're trying to shove some really large axles in there.

Eric

Yeah they said we needed about an inch or so, and evasive didn't want to grind it down. Originally before I even talked to Driveshaft shop about the issue that was my response, was to grind the knuckle down where it was making contact and they scoffed at me lol. And the Pro axle kit I have is the 1000 HP units, the outside spline is larger so it's kind of impossible to put these in backwards. Not to mention there is only 1 threaded side.

On second look and thinking about it, it does look like a risky place to cut. That part of the casting is where the compressive stress (torsion) flows into the upper control arm. One hard pothole and *poof*.

It's really impossible to guess just by eyeballing it. One could estimate the loads to get a feel for the design factor of the unmodified unit. If it's huge then maybe...