After cutting the ends off each axle, I used a disk sander to bevel the sharp edge and a small file to knock off the sharp edges around the splines so they would easily slip into the differential during assembly. I've indicated the witness marks in the photo above that allowed me to figured out how much of the housing I could have removed without having to get new axles built or have these resplined. Notice the shiny wear marks along the sides of the splines where the gears in the differential ride on the splines. I had over 1/2" of unworn spline indicated on each side so was confident that narrowing the housing by 3/8" would not cause any problems. Next –––>

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