The first step in assembling the axles was to dowel pin the Miter gears to the Axle Shafts. This picture shows the first step, drilling the pilot hole.

I ended up making a hardened set of Miter Gears, check out the Miter Gears to see how they were made.

I then used a Wire EDM to size the hole for a perfect press fit with a 1/16" dowel pin.

This picture shows another view of the hole being sized on a Wire EDM.

I also pinned the drive shaft side of the miter gear set.

This picture shows the wire threaded and ready to size the hole.

Once the Axle Shafts were pinned with the gears, I pressed all the bearings into the Axle parts.

This picture shows the gear inplace in the Pumpkin Housing and the gear inplace in the Axel Tube ready to be assembled together.

Here you can see the Housing bolted to the Axle Block with the gears in perfect mesh. I then put a bunch of Teflon grease on the gears and sealed the Axle with the second Cover and Axle Tube.

I used two 1x2x3" blocks and a granite plate to preset the two half of the Axles in perfect alignment.

Once preset in the correct position, I locked all the screws down tight.

The next step was to mate the Axles with the Steering Arms and Suspension Arms. This picture shows the pile of parts ready to be assembled.

At this point, the Suspension Arm is bolted on and the two Steering Arms are connected to the Hub Blocks.

Heres a picture of me presetting the Tow Alignment by bolting the Steering Arm Link inplace.

This picture shows the almost complete Axles with the Hub Blocks turned right.

This picture shows the almost complete Axles with the Hub Blocks turned left.

This picture shows you how the two Axles sit in the truck, this also gives you an idea of how my custom designed ©HYPER-GYMBAL suspension works.

This picture shows a completed Axle with U-Joints inplace.

A finished Axle sitting on the master check list of parts that I used during the project. The % done was taken from this list during the build days.

The Axles have been upgraded, check out the 08/00 Mods to see the current Axles.