Inner Axle Groove

[Chester]

That might have been possible but probably not the best method. I have done stuff like that too on my old fj40, but ended up having to redo the job again cause it failed. So spending the money on cheap axles now hopefully will save me later.

I found one once where the PO had put the seal in backwards, I assume it was done that way to contact the axle in a different spot, and it must have worked, it wasn't leaking when I took it apart and replaced the axle.

 

[LINUS]

On the broken bolt thing, I've also used a Dremel with a high speed steel cutter tip to slot it & used a impact driver (you hit the end with a BFH, it rotates) - or like the other guy you could get lucky with penetrating oil, heat, (a MAP gas bottle will get it pretty hot when you run your acetylene bottle out **cough cough**) also a combo of both works like a multiplier.

 

[erose54]

So the small bolt stuck in the knuckle housing is the least of my worries now I guess what they say is true, Don't go looking for trouble if you don't want to find it.

I am going to assume that the birfield was run dry by previous owner for awhile. There are chips, deep groves, scratches and burn marks.

Passenger side birfield images:

 

[erose54]

Here are more images:

 

[erose54]

New axle shafts arrived today. But I am still working on getting birf or birfs to replace the chipped one.