Outer Limits 4x4 Board

Well I snapped the left side one this time going up a very steeply rutted/rocky climb today, got three quarter to the top and blam !!!!
At least it's the non driven axle this time and must have broken at the spline because the axle is not flopping around (must be still supported by the locker collar). Could have been fatigued from when the right side snapped (6 months ago) but not visible to the naked eye as it looked fine when we had it out.
Oh well off to the wreckers tomorrow for a axle.
I still can't believe Swartzy hasn't broken a rear axle..................
Well it's all part of the game

Bitsamissin wrote:Well I snapped the left side one this time going up a very steeply rutted/rocky climb today, got three quarter to the top and blam !!!!
At least it's the non driven axle this time and must have broken at the spline because the axle is not flopping around (must be still supported by the locker collar). Could have been fatigued from when the right side snapped (6 months ago) but not visible to the naked eye as it looked fine when we had it out.
Oh well off to the wreckers tomorrow for a axle.
I still can't believe Swartzy hasn't broken a rear axle..................
Well it's all part of the game

Frank what are you going to do to it with sticky 35's on.

Any plans for more beef or at least gear it down for less mumbo and di you get that front locker you were after

Yeah Singo I've been thinking the same thing.
I can get some beefier axles made up by Mark Hardman (I spoke to him about it when I busted the 1st one).
I honestly believe the rear is doing all the work and the front is doing nothing, the front locker is 2 weeks away and will help balance the stress load.
But I have to sort it out before 35"s otherwise it will be a regular thing.

Bitsamissin wrote:Well I snapped the left side one this time going up a very steeply rutted/rocky climb today, got three quarter to the top and blam !!!!
At least it's the non driven axle this time and must have broken at the spline because the axle is not flopping around (must be still supported by the locker collar). Could have been fatigued from when the right side snapped (6 months ago) but not visible to the naked eye as it looked fine when we had it out.
Oh well off to the wreckers tomorrow for a axle.
I still can't believe Swartzy hasn't broken a rear axle..................
Well it's all part of the game

Frank have you pulled the axle out yet......Shane

Hey Frank,

I posted this on the wire, but I figured I would post it here as well.

I was thinking you might be able to take the side gears off the diff, and broach and spine them for the 3.5 shafts. You might have to gun drill the housing out to take the large shafts and bearings, but the dana60 guys have done it before, and you get a big improvment.

Just something to think of. The improvment would be better than a stronger heat treated shaft, and you would still have junkyard axle shafts to choose from.

Earth to Frank ... so what are you doing with the rear axle?

I looked at the side gear option and there just ain't enough room, sure you can get new side gears cut but it's getting the bigger axles through the carrier bearings and housings. There's just too much work in it.
I spoke to our gear cutter today and he is going to cut me some axles that he wreckons will be 2-3 times stronger. Cut out of some exotic material that all the drag racers use and heat treated using a different process. He says these things can twist a full rotation before they will snap
Cost around $700 Aus for the pair. Remember a new axle from Mitsu is $500 Aus and a 2nd hand one from a wrecker is $250 Aus.
If I break these then I'll put a friggin Dana 90 under it...................that should fix it

Bitsamissin wrote:I looked at the side gear option and there just ain't enough room, sure you can get new side gears cut but it's getting the bigger axles through the carrier bearings and housings. There's just too much work in it.
I spoke to our gear cutter today and he is going to cut me some axles that he wreckons will be 2-3 times stronger. Cut out of some exotic material that all the drag racers use and heat treated using a different process. He says these things can twist a full rotation before they will snap
Cost around $700 Aus for the pair. Remember a new axle from Mitsu is $500 Aus and a 2nd hand one from a wrecker is $250 Aus.
If I break these then I'll put a friggin Dana 90 under it...................that should fix it

can he make shafts for anything? eg volvos?

i might narrow my housing then 8)

Sure he can Nam call him (Mark Hardman) 9551 5566.

Frank.

$700 a pair - what a bargain!!!! when i snapped my rear left it was gonna be $850 from mitsu and 4 weeks out of japan for a factory rear locker axle. there were none in wreckers anywhere so i had an open diff axle shortened and i got that one for $120 in mint condition. what breaks next after the axle once you beef it up 2 to 3 times stronger?

redrocket wrote:what breaks next after the axle once you beef it up 2 to 3 times stronger?

My money is on drive shaft u-joints... or the ring and pinion.

You guys forget the critical issue here the axles are still 4 cylinder size :-
2.6 = 30.5mm diameter, 28 spline.
3.0 V6 = 30.5mm diameter, 28 spline.
3.5 V6 = 35.5mm diameter, 31 spline.
With a lwb and rear locker plus 33"s & 5sp I think their on the limit.
The crownwheel and pinion gears are chunky as all hell and stronger than a Hilux and 9" diameter (Hilux is 8"). A Lux will run 36"s all day long as they have 31 spline, 33.3mm diameter axles.
I believe the week point is the axles but the rest of the running gear is as tough as nails. Case in point no-one has reported a 3.5 V6 rear axle failure from wheelin. The front locker will also help balance the stress front to rear.

bootie some ZOOK diffs under it !!!!!

Gee what a great idea, why didn't I think of that

Frank,

Think he could make more axles down the line?

Bitsamissin wrote:Case in point no-one has reported a 3.5 V6 rear axle failure from wheelin.

Yep, had mine nearly standing on it's end a few times, fully crossed up and still climbing. The only noise I heard were those farken lash adjusters running out of oil ...

Well seeing your a top bloke Kris and obviously a sh1t hot offroad driver and your selling the Paj......................
How about doing a rear end swap with mine before ya sell it
At least you will have a ARB compressor out of it
Should only take us a weekend and I'll through in some beverages

Bitsamissin wrote:Well seeing your a top bloke Kris and obviously a sh1t hot offroad driver and your selling the Paj......................
How about doing a rear end swap with mine before ya sell it
At least you will have a ARB compressor out of it
Should only take us a weekend and I'll through in some beverages

Frank, wipe your nose ... she's alookin a bit brown. :wink:

Kris mate, did I mention the half inch of extra under diff clearance you will have with the 9" pumpkin eh buddy, friend, pal.................
Alright, alright I'm going (wiping brown stuff from my nose with a tissue)