Knuckle Shim Gap Too Big?

Hello all. I'm installing a new set of knuckles and bearings and it seems like it's taking too many shims. Something like a quarter inch. I measured the new bearings and they are the same thickness as the old ones, and the races are fully seated. Is this a problem or can i just stack a bunch of shims. The knuckles are off a Wagoneer Dana 27 and only had a few shims on each side when I pulled them. I attached a picture of the gap when its finger tight.

 

I haven't quite got to that point. i have stacks of old shims and a new pack. I threw about ten random shims in to start off and it wasn't enough to take up the gap. To me it seems like the gap is larger than it should be. When I pulled the old knuckle off it had around 4 shims in it. I have a pull scale so I was planning on setting it to the usual 12-16 ft lbs.

 

Are you sure the knuckles came off a 27 and not a closed knuckles 44. Sure the inside diameter of the bearing is the correct diameter almost sounds like the king pin isn't sliding into it.

 

Yeah it's definitely a Dana 27 it's stamped on the pumpkin. I test fit the bearings on the caps and they slide on easily by hand. I guess at this point I'm just gonna measure everything against the old axle and old parts.

 

Did the bearing caps slide in while everything was on the bench? I always check that before putting the parts back on the axle.
Bearing races fully seated in the axle?

 

I did test fit them first and they slipped on fine and seated all the way. I also tried a different cap on the top and got the same gap.

 

Also, try installing the cap without the bearing being in place to make sure it is not hanging on the shoulder of the studs. Make sure you have the caps in correct position, upper and lower are milled differently on later axles.

 

I'll mess with some more later today and take some pics. I did use the correct timkin bearings and races. It's possible I have the caps installed wrong I'll have to check that.

 

Did the knuckle have studs originally?
We're the caps marked before removal?

 

I added the studs. i did mark the caps but it's possible I mixed them up at some point during cleaning. i was under the impression that they are all the same.

 

Well I think I got it figured out.i just needed to tighten it down more and it pulled the gap in. Ended up taking 4 shims to get a good preload. Thanks everyone for the tips!

 

Glad you got it sorted out.