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Each end of a half –shaft has 2 “mounts” for a universal joint. (I don’t know the proper term for this part of the shaft. What I am calling the “mounts” are the parts with the holes that the universal joint caps slide into.) How much wear on these “mounts” is permissible? I have observed that the tops of the “mounts” are somewhat thinned on the inboard side (that is, the joint side). Also, the "mounts" on the flanges that connect the universal joints to the rear spindles seem to be thinned in a similar position and manner.
The components of the half-shaft that you are describing are called "yokes". These are welded to the tube section to form the half-shaft or driveshaft assembly. Virtually no wear on the INNER surface of the yoke eyes (where the u-joint caps reside) is acceptable. However, I believe that the "wear" that you're referring to is on the OUTSIDE surface of the part. For whatever reason, these often appear "worn", but that's how they are brand new. It's just the characteristics of the particular forging dies used to manufacture them.
Thank you. I guess there was a different technique used for the main drive (propeller)shaft, since there is no similar thining on the drive shaft yokes.
Consider that the halfshafts travel through considerably more angle than the prop shaft. The "wear" you are describing is either in the forging dies or may actually be from a machining operation to provide additional clearance so the joints won't ground out through their design range of travel.
The half shaft drive flanges on '63s actually do ground out against the yoke at full rebound, which is a design error. The end flange was redesigned later in production.
Yes, the 1963 half shaft flanges were much "thicker" in cross section and they were manufactured of nodular cast iron. For the 1964 model year the flange was redesigned and was manufactured of forged steel with a "thinner" cross section. It's possible that this piece could have been used for late 1963, also. This piece was then used through 1974. In 1975, a new flange, also of forged steel construction, was introduced to PRODUCTION and it became the SERVICE piece for all 63 to 74 Corvettes, too. The latter part, manufactured by Dana-Spicer, is still available from GM.
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