Ok, I am rebuilding an 80-83 axle for my SAS and I have a few questions.

First, what is the best way to smooth out the rust pitting on the balls and the flat mating surfaces on the front and back of the knuckles? It isn't bad but at least on the balls I would think that the seals will last a little longer if the surface was a little smoother.

Also the lower knuckle bearing dowel pin has a little groove on it from the old bearing. What is the best way to get rid of that?

On 4Cralwers site he talks about sanding the balls but doesn't say how. By hand what grit paper ect? He also talks about removing the ridges.grooves whatever on the dowel pin but doesn't really say how.

I just don't want to mess up this axle by doing something I shouldn't.

 

Doing my best possible Eric Cartman imitation, "must resist replying to question about using sandpaper on balls...must resist replying to question about using sandpaper on balls...must resist replying to question about using sandpaper on balls..."
Sorry, it has been a long week. I've tried three times already to stop myself from posting this...whoops, four now...I HAVE TO DO IT!

 

Ok, I did it and I apologize. I'll delete it after an inappropriate amount of time has passed.

 

Haha I knew someone would make a comment like that. At least I didn't talk about how much grease was all over my balls, or how crusty they were

 

the outer ends of the axle can best be resurfaced with a small(2-3") DA sander. at least that's what I use. try 220 or higher. any more coarse than that and you'll end up with deep gouges and leaks.

 

100 grit then 50 grit to get it all roughed up

 

I did this on my 79 cruiser axle that came from Canada (= salt = rust).

(I will disregard all comments)

First I disassembled the whole thing (You must already be there)
Then I put a wire brush in an electric drill and cleaned all the rust from my balls. Them smoothed my balls with 150 emery paper. I still had some pits, but figured it wouldn't hurt anything. ( Later I thought it would have been better if I had JB welded them to fill them in) I spray painted the balls with epoxy primer, and finished with gloss epoxy paint. There is no "load" on the ball sealing surfaces, just the wipers.

I have not had any problems since the build.

Do you have a photo of the "groove" on the pin? Is it on the bearing race or the pin itself? I replaced bearings with KOYO (oem) as the bearings had the grooves on them. It would almost lock when turning, you could feel it in the steering.