Rear hub nut tightening

[Alan]

For the joint to work properly, the drive has to be through the taper, not the key. So, the hub and shaft need to fit together properly. If you push the hub onto the shaft, you should need a puller to get it off again. If not, you need to lap the parts together until they do fit. I know this will get howls of protest from BC, but trust me, I’m right. Then you need to make sure the hub isn’t riding up on the woodruff key. Fit the parts together with no key and count how many flats the nut turns to be finger tight. Take it apart and when you assemble with the key in position you should get the same number of flats. At the same time check that the nut is bedding on the hub and not the shoulder below the thread in the half shaft. The gear fouling inside the casing has already been mentioned. If you do all of this , 120ftlbs is perfectly ok on the spanner and you won’t be wrecking halfshafts.