(10/21 UPDATE fixed) Wheel bearing failed.

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I've been wondered if the nuts could walk off. With snap ring and caliper as a safety's holding rotor/hub in. Seems the answer is YES!

I've seen my share of lock washers not properly set, then locking and adjusting nuts loosing. But I've never even heard of a 100 series hub walking off the spindle..

Preliminary parts list;
Differential side oil seal (advisable when replace FDS).
FDS (AKA CV).
Rotor.
Wheel bearing and race set.
Hub oil seal.
Claw washer.
Adjusting and lock nuts, wheel bearing.
Lock washer.
Hub flange gasket.
Hub flange.
Snap ring, fitted for gap.

Close inspection for possible damage and replacement:
6 cone washers.
Steering knuckle.
Wheel bearing hub.
Caliper & pads (Pads on both sides may be advisable & machined other rotor)
Wheel Speed sensor.

Curious:
Is the rotor OEM?
Were the two spindle nuts and a lock washer found in grease cap?

thanks very much for the list. this is very helpful.

im not sure if the rotor is OEM, but I ordered a BOSCH Rotor and Pads to replace it. I can return them if OEM is the way to go.

The caliper is gtg, will have a brake flush and will repack my RH bearings on the other side.

Im gonna clean up the items in the hub and take pics for a full autopsy
 
thanks very much for the list. this is very helpful.

im not sure if the rotor is OEM, but I ordered a BOSCH Rotor and Pads to replace it. I can return them if OEM is the way to go.

The caliper is gtg, will have a brake flush and will repack my RH bearings on the other side.

I'm gonna clean up the items in the hub and take pics for a full autopsy
Bosch was once a good name, if still the case today I can't say. Many go with aftermarket rotors. Either to save $ or too get into slotted and drilled.

I do see cart loads of car-quest rotors going into Wholesale parts dep of/for the shop of local Toyota Dealership. The same shop front end specialist master mechanic has told me; they see warp issue with non OEM rotors. So checking run-out, of even new rotors, is a good practice.

_________

Here's why I'm very interested to see "full autopsy".

I've seen my share of preload not set and wheel bearings set to loose when serviced.
Also where lock washers not properly set. Some where all tabs bent in, not locking adjusting nut to locking nut. . Some where the key/keep of lock washer was worn down to point it should not have been reused. Some, where no tabs of lock washer bent, being the worst case. I see that a lot from ASE cert mechanics, even from Toyota/Lexus Dealerships.

My 2001LC which I had almost 15 years. Shamefully, I did not do a wheel bearing service until 40k miles after purchase. I never even checked for loose wheel bearings, as bearings were serviced at a Toyota Dealership, my bad. On it's first wheel bearing service that I did, at 98K miles on odometer. I found DS lock washer was without even one tab bent, so not locking wheel bearing nuts at all. Claw washer was deeply scored and spindle showed indications (bluing) of high heat build up. Back of spindle where large bearing butts against, was badly scored. Which indicates hub was move in and out some, pounding of back of spindle. These were very loose wheel bearings nuts and not locked at all. Also this being DS means forward wheel spin can spin off nuts of DS side, as they are standard right hand threads.

So here is my case of DS with wheel adjusting and locking nuts not locked and loose. Yet over 40K of driving this way they did not walk off the spindle. But is was almost all HWY and city streets, with very little and lite wheeling.

Yours walked off, a month after a studs repair?

My guess your hub had already walked off to the point where great deal of pressure (angle) was on rotors disk within calipers hold. You came down on DS tire hard, from the three point. At that time your fracture the disk at rotors hub and possible popped the snap ring off at same time. Then wheel bearing nuts just spun off as you drove after this. Losing safety of disk riding in caliper which was now fracture and snap ring both have effect of holding on wheel hub. That with disk separated, the area between hub flange and spindle threads grew enough too allow nuts room to spin off.

So pay close attention as you remove grease cap and hub flange, as to what parts are seen and what order parts are in. Should see in this order: grease cap, snap ring, hub flange, hub flange gasket, lock nut, lock washer, adjusting nut, claw washer, small wheel bearing.

Would be a good idea to video tape with a friend present.

BTW: Snap ring is non reusable part. Whereas I do not think this was cause of failure. The shop that replaced the lug should show snap ring on parts list. It shows if they followed or didn't follow the factory recommended procedure.
 
Probably unrelated, but on older land rovers there was an issue with the brake pads comming loose in the calipper (can't exactly remember why though, maybe the retaining plates/springs?) & basicly machining off the brake disk like a lathe.
 
10/14 update
here are the 2 studs that were replaced:
11YcLdU.jpg


grease cap off and snap sitting just like that:
6Of7puP.jpg


flange off:


-not sure if the claw washer disintegrated or was missing
-no sign of the flange gasket

do i need a new hub? or can this be re-used- its only one tooth:
MdrlApA.jpg

if replace, where can i source a reman or used one? the new ones are $300+
*****nvm, bought a new in box from ebay:

also, any tips on removing this 24mm nut so i can remove the spindle and install my new cv?
rIU6jvg.jpg

impact gun/ heat/ breaker bar/ pb blaster isnt working
pPduofh.jpg
 
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I've been told never to use heat on these components. BTW, judging by the marks on the castle nut -> are you doing it in the right direction? What is that "thing" below the castle nut?

1571061745323.webp
 
I've been told never to use heat on these components. BTW, judging by the marks on the castle nut -> are you doing it in the right direction? What is that "thing" below the castle nut?

View attachment 2107193

it looked beat up w a hammer when i check it. nothing there. by direction, this isnt backwards is it? im going counter clockwise to remove it.
 
it looked beat up w a hammer when i check it. nothing there. by direction, this isnt backwards is it? im going counter clockwise to remove it.

I would get good used parts to replace the major components affected, and get all new hardware and seals and bearings, if it were my truck.
 
it looked beat up w a hammer when i check it. nothing there. by direction, this isnt backwards is it? im going counter clockwise to remove it.

Interesting.. Yes CCW it is (but it is upside down).
 
I would get good used parts to replace the major components affected, and get all new hardware and seals and bearings, if it were my truck.
yeah im looking for an LCA now also. i dont trust the aftermarket ball joints and toyota doesnt sell them separate from the lca
 
Your claw washer is there. It's the last washer you pulled out before the bearing.

The lock washer, is one, that is all mangled and only partial remaining. The lock washer is so mangled, you'll never know if it was locked in properly. But that FSM calls it "non reusable" same for snap ring. Lock washers are routinely reused, but to reuse, they must have a good keep and two unbent tabs in usable location. The tabs can only be bent once, as re-bending weakens them and then tab can easily fail. The keep is important also, as it helps keeps lock washer from spinning on spindle.
Steering Knuckle, wheel bearing & axle hub 065 (2).JPG

I would replace that wheel hub. It may give wheel speed sensor a bad signal, even after reconditioning. Then you'd have wasted time and a new set of wheel bearings & races.

Looks like castle nut has been smashed onto ball joint stud and stud threads are mangle to one side. Assume you are turning CCW to remove. I'd say nut and stud are mangle so much that is locking nut on the stud. I'd cut off castle nut at about the red line.
rIU6jvg.jpg

More you cut off less resistance from damaged nut and stud threads. But less nut you'll have to grab with socket. So it a it your call on how much you cut off. Extractor socket may be needed, if you can't get a good bit.
image_25021.jpg

Of course you'll need a new ball joint (555) after cutting it's stud. The 555 ball joints are what everyone uses, they've held up well based on mud accounts.

If you don't get it off, you'll need a replacement steering knuckle also. With the LCA you're now considering...
 
I've had castle nuts stuck on for whatever reason. I've had good luck taking a Dremel tool or die grinder and cutting vertical through one of the notched areas of the nut then taking a small cold chisel and breaking the nut. It may be easier to cut the nut on both sides and split it in half. Not sure of the hardness of this particular nut. Some break easier than others.
 
A rotor failure would not cause this. if it did, you would see the threads for the large nuts be damaged because they would have needed to be ripped off the threads. Clearly the lock nuts backed out. The outer disc of the rotor has no structural bearing on the hub assembly, and to me broke asa RESULT of the hub failure.

Also not sure if there is confusion on this, but the c clip on the axle does not hold the hub to the spindle in any way shape or form, it simply holds the CV in place INSIDE the hub. The c clip coming off would never cause a hub failure. The hub is held on by the big 54mm nuts and lock washers.
 
Incorrect assembly. The star washer was not between the 54mm nuts as it should have been. It was between the inner nut and the claw washer.
 
Hard to say where they placed that lock washer. One think I've no doubt, it was improper wheel bearing assembly, that lead to wheel bearing nuts walking off.
 
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I've had castle nuts stuck on for whatever reason. I've had good luck taking a Dremel tool or die grinder and cutting vertical through one of the notched areas of the nut then taking a small cold chisel and breaking the nut. It may be easier to cut the nut on both sides and split it in half. Not sure of the hardness of this particular nut. Some break easier than others.
This^^

Cut it off with vertical cuts in 2 pcs.
 
I agree with @atnolan94 and @subzali and others. The 54mm nuts are the only fateners/retainers that keep the hub on the spindle. They must have backed off, which means improper assembly, either wrong order of lock washer or just way too loose and not per spec.

After the nuts back off, the only things keeping the hub on would be primarily the disc brake held by the caliper, which surely would have been grinding. Likely that landing on the wheel snapped the disc. As mentioned by @atnolan94 the C-clip holds the axle inside the hub, not the other way around. But once all else let's go, it would the the only thing in the way of the entire wheel/hub falling completely off. You showed pictures of how the splines were completely worn, probably by the clip, and the clip eventually fell off. So they are definitely taking wear. Hard to say what went first, the C-clip or the rotor.

In any case, I still say this points to failed workmanship and is the fault of the shop that replaced the studs (assuming no other work was done after that). This is by no means an inexpensive repair, and the shop should be held accountable. Leave a Yelp review at least, see how fast they get back to you. You are lucky this happened on a trail and not somewhere else, like the freeway.
 
Hard to say where they placed that lock washer. One think I've no doubt, it was improper wheel bearing assembly, that lead to wheel bearing nuts walking off.

You can see it in the video. He pulls out the outer nut, then the inner nut, then the mangled piece of star washer, then the claw washer, then the bearing. He should take the video with the FSM page back to the people who worked on it and show them it was in the wrong order and the star washer was doing nothing, and especially not stopping the nuts from backing off as it is designed to do.
 

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