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C-Clips (c-washers really) in the rear diff on semi-float? I don't see a true BFH on the ground either.
No c-clips in semi-floats. Just unbolt the hub/shaft assy and it should pull out (done it before).

Not sure how anyone expects me to add heat to the internals of the axle housing. I guess i could light a fire inside it 😂

I actually don’t own a BFH any bigger than the one pictured. Never needed it until now i suppose
 
Got it. Now the issue is that I can't get it back in...the bearing is slightly dislodged. I'll try to press the bearing on and see if that gets the shaft in further

Might be time to throw in the towel and buy another shaft altogether...

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Semi-float is some bullish*t. So are OEM rear lockers when you're really using them

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The shaft I broke back in November broke at the same place. Seems to be the weak spot on the 100 semi floaters (at least the locked versions)
 
What finally got the shaft to dislodge at the hub?
Yesterday I was attempting to pull the shaft out of the hub assembly. Today I pulled the entire assembly with relative ease

Now I can’t get it all back in because I managed to pull the shaft off the hub slightly yesterday…gotta press it back on then i can re-assemble

Here's the old 80 thread on the subject of OE rear lockers being less than ideal- Twisted rear axle shaft - https://forum.ih8mud.com/threads/twisted-rear-axle-shaft.239583/post-4572152
 
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Here are some relevant threads I've stumbled across in regards to this.
I'll be attempting to "machine down" my splines on this shaft with a grinder/flap disk next week. I plan to replace the shaft eventually and will have that one milled on a lathe.


Apparently the drawing in this post from @landtank is inaccurate. I can't assume that the 100 shaft is identical to the 80 since they are 32 spline vs 30 spline.

I doubt many 100 owners have had this issue yet and if they have I need to meet them.
 
Is it possible to run standard LX shafts without the longer splines with something like an airlocker?
 
Yes lots of 80 guys have had this discussion. Christo chimed in a fair amount back in the 2010s recommending something like an ARB to prevent this issue

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I’ll be buying a spare shaft soon. Not sure what I’ll do long-term. It will honestly depend on future problems which will hopefully be minimal now that I’m more cognizant of this “feature”

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“Welcome to 37s” - Jason Bush
 

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