What is it: Ouverson's Violator Series Axle Conversion
Why it is cool: Most stock Rockwell axleshafts feature 16 splines. The Violator Series axleshafts feature 47 splines and come with a lifetime warranty against breakage. Included with this upgrade package are inner and outer shafts, seals and retainers, drive flanges, and your choice of locker or spool. Ouverson recommends upgrading to the Violator Series U-joint when performing this conversion.
What is it: Ouverson's 4.90:1 and 6.73:1 Gear Sets
Why it is cool: In stock form, Rockwell 2.5-ton axles come with a 6.72:1 ratio-not exactly a highway-friendly combination. Furthermore, the factory gears were designed with low-torque multi-fuel military engines in mind. Add additional power to the equation, and the stock gearsets start to wear out quickly and even break in some circumstances. The solution: replacement gearsets from Ouverson Engineering. Not only does Ouverson offer an all-new 4.90:1 ratio, but also the improved gear design enhances tooth engagement significantly over stock. Thanks to better materials, deeper tooth grooves, and a more robust ring design, the Ouverson gearsets can handle monster truck power and tire sizes without issue.
What is it: Ouverson's Third Member Stud Girdle Kit
Why it is cool: When you mix big tires with high horsepower, the stock Rockwell third member can develop problems. The excessive power causes the gears and bearings to deflect, resulting in improper wear and eventually failure of the third member. This billet steel Stud Girdle kit solves the problem by tying each side of the main bearing caps together, eliminating any possible deflection. The unit ensures proper gear mesh no matter how much torque the unit sees.
Build Strategy 2 - Working Man's Budget
A TTC Worthy 2.5-ton
When a Dana 60, 70, or 80 is not enough beef, but you don't want to sell the farm to afford the parts needed to go bigger, look into Boyce Equipment of Ogden, Utah. Boyce stocks new, rebuilt, and used front and rear 2.5-ton Rockwell axles that are ready to ship. Boyce also offers individual stock replacement parts like locking hubs, pinion-mounted brakes, third members, and seal kits to complete your Rockwell axle build. Boyce can also modify a Rockwell to your specs using custom axleshafts, U-joints, axle boots, wheels, or steering components-including full hydraulic conversions or any other part you might need.
Info: Boyce Equipment, 800/748-4269, www.boyceequipment.com
Finding Inexpensive Rockwell Axles
The military used 2.5-ton Rockwell axles in troop carriers for many decades. Today, these vehicles can be found rusting away in virtually every corner of the country. We found one listed for sale on the Internet for $1,000 or best offer. The only catch: This truck did not run and it was the buyer's responsibility to haul it away on a trailer. If you stop and think about it, three 2.5-ton axles for $1,000 is not a bad deal.
What is it: 2.5-ton Rockwell Rebuild Kit
Why it is cool: You get everything you need to ensure that your Rockwell axle is leak-free and ready for action on the trail. The rear axle kit shown here includes two spindle seals, two outer seals, two flange gaskets, one pinion seal, and one differential gasket. Kits are also available for front axle applications and include knuckle boots as well.
What is it: Complete Rockwell Axle Assemblies
Why it is cool: These axles are built using the latest and greatest factory-style internal parts and can be upgraded in many key areas for improvements in strength, traction, braking and steering. The best part about these assemblies is that you get outstanding upgrade in axle strength at an affordable price.