Outer Limits 4x4 Board

RUFF wrote:Sam remember these breakages at Rover Park? Ive also broken other hilux axles exactly the same. No twists in the splines. I think it also has a lot to do with the material the axle is made from. Patrol Cvs usually break exactly as you expect. Thats in pieces not clean breaks. But must toyota axles i have seen break have been clean cut.

Yea - true.

I guess I can handle a forged factory axle breaking anywhere without hurting the splines. Like factory 60 series rear axles always break easily at the forged drive flange area like somebody cut it with a hacksaw. Factory forged axles do break in strange ways.

I think in NAMs case he has got stuff hitting on other stuff and thats what is breaking them...it almost looks like its got wear marks right up the inner end of the splines??? Which would mean the alxe is a long way into the CV...whould explain the marks on the end of the axle and the ones around the circumference to the right of the break.

I could be wrong though...

Sam

i think you're right sam. the end of the stub is damaged - consistent with bottoming out inside the bell. can't see cos it's full of grease still.

this axle has no circlip grooves. when i make a new one, i should run circlips... or a tack weld.

gonna take all these ideas to the axle maker and hopefully get something a lot better than what this was.

So this is at the CV end? I assumed it was at the Centre end due to there being no circlip groove. If it is the cv end it defianatly needs a tac weld. I dont think i would run a groove it will be a weak spot again. How many axles has this housing broken so far? I thought it broke a couple when Sam still had it.

yeah it's done a few with me. not sure how many sam went through. cal snapped a few of his as well. they're too short. i had to upgrade the hub studs to bigger cap screws on the short side (front and rear) but the long side is still stock. there's just no give in such a short axle.

i broke both my front axles in my GU last weekend they both broke exactly like NAMs clean break no twisted splines no damage from bottoming out no CV joint damage just clean break on the end of CV end spline. right hand (short axle) went first then when i tried to reverse the left snapped instantly. these axles and CVs are the original ones that were fitted to the vehicle new. truck has done 100000km ,i put it down to fatigue but i thought the CVs would have given up first

Same on the rear of an OE Disco2 semifloating axle.

Most axles and shafts will clean shear like this, due to the case hardening. If the axle were through hardened it would brake at jagged angles like sam described.

nastytroll wrote:Most axles and shafts will clean shear like this, due to the case hardening. If the axle were through hardened it would brake at jagged angles like sam described.

My cheese sticks didn't come with the plastic wrapper.

N*A*M wrote:i think you're right sam. the end of the stub is damaged - consistent with bottoming out inside the bell. can't see cos it's full of grease still.

this axle has no circlip grooves. when i make a new one, i should run circlips... or a tack weld.

gonna take all these ideas to the axle maker and hopefully get something a lot better than what this was.

you cant get a custom inner straight from longfield?

id say they would be your strongest bet