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Yeah, I'll have to look up the date on the Harrop, I had an ARB first ( it sucked ). Yes on the pitting on the splines we are talking about. It looked like water had gotten in the drive flange and started to rust the splines. The pass. side was fine, due to a leaking oil seal. I didn't realize the splines needed to be greased.
 
Front Range got back with me via email and just claimed it was due to loose or over tightened wheel bearings. :meh: Honestly I've never seen totally destroyed wheel bearings. Sure some pitting, but that was due to years worth of neglect on trailer bearings. Either way, I need new parts and start over. Something that I'll have to pull and check each Winter.
 
It would most likely be the other way around. When everything is the way it should there is an air gap between the axle and the bearing hub, those bearings would be glowing red hot and be a problem long before you transferred enough heat into that axle to do what you did.
More likely the axle broke and that end was dragging on the inner side of the bearing hub and the heat that was created from that took out your bearings.

Hmmm quite opposite from what J Mack said which makes better sense to me. Ron are you going to go back with Front Range for parts to repair or try different route?
 
I believe the only parts I need from them is their drive flange and inner axle seals. I know a bearing and seal company in St. Louis, so I'll try to get the seals there. I think the axles shafts can come RVC direct, but without a good shaft to measure from, I'm not sure. I did ask Front Range that question. All the other parts are stock FJ60 and 4runner brake parts. I do like the Diamond housing and what Front Runner has put together, but when they went to just email costumer service went down. I like to talk to people about problems. Even my kids don't want to talk anymore, they text. :meh:
 
I believe the only parts I need from them is their drive flange and inner axle seals.
My Drive flange came from RCV and I believe it's an 80 front drive flange. Kurt will hook you up with Marlin seals.
Take your own measurements, RCV will walk you through the process.
Check you housing for straightness before you reassemble.

All else fails send it to me and I'll do all of it for you.
 
I believe the only parts I need from them is their drive flange and inner axle seals. I know a bearing and seal company in St. Louis, so I'll try to get the seals there. I think the axles shafts can come RVC direct, but without a good shaft to measure from, I'm not sure. I did ask Front Range that question. All the other parts are stock FJ60 and 4runner brake parts. I do like the Diamond housing and what Front Runner has put together, but when they went to just email costumer service went down. I like to talk to people about problems. Even my kids don't want to talk anymore, they text. :meh:
Ron, no one does 😯😲🧐🤔. Talking is becoming an Art Form! Feel like Smashing my phone sometimes 😒😡🤯🤬😉😯😲🧐🤔😳😘👉🐖👈
 
Yes...
Looking at the splines that are outside the flange they still have flats, the splines that are in the flange look to be pointed like they are fretting in that hub.
Something is out of alignment for that much wear in this short amount of time, IMHO.

Jim is correct. There is definitely an alignment issue in play here based on the wear. I agree with him that the axle housing should be pulled and checked for straightness. Perhaps the housing is bent slightly due to the weight of your truck.
 
Perhaps the housing is bent slightly due to the weight of your truck.

The answer I got from Front Range "this is on one of our Diamond housings, so that is not a concern" It is one of their selling features, very thick tubing walls and I don't jump the wagon. They are confident it was due to loose wheel bearings. I will look into having it checked.
 
Just to add some tech on the axle housing, the tubes are 3/8" thick DOM. Those housings are made for racing/king of the hammers sheet, Scrapdaddy isn't going to bend one. The only possible way it's bent is from the factory in my opinion.

 
After looking at Diff on there web 🤔🧐 3/8 dom which is very Stout. My questions would be 1 @J Mack said after welding and 2 what material thickness was used on the housing itself🤔🧐, and what material and heat control is done during weld and assembly?? So you have Stout axle tubes and from what I see as a weak link is the fabbed diff housing, with the excessive heat during welding causing a an issue with material integrity 🤔.
 
I understand what you're saying, but I have to believe they check and double check that before leaving their shop. Like Bob says I'm sure it sits in a fixture when welding, but I'm not certain of anything right now. A small company wouldn't be around long sending out bent housings to a client base of rock crawlers and off road racers. Their whole business is based on the beefiest housing out there, but I'd be the one that got a bent one.
 
I count at least 16 different welds on the diff housing alone😲😳😯 and were the housing meets the axle tubes if they didnt bevel the material it would compromise the penetration. I would ask for C of Cs on the materials both housing and axle tubes and ask for weld coupons that that were submitted and passed by a metallurgist 🤔🧐. If they are not willing, I would shop elsewhere. Ya ima bitch. But I dont like friends getting Screwed 😲😳🤔🧐😘🐷
 
Scrapdaddy isn't going to bend one. The only possible way it's bent is from the factory in my opinion.

Kind of my thoughts as well, along the same line as not wheeling it hard enough to break an axle shaft. Not saying there couldn’t be some misalignment somewhere, because I’m still not getting why the axle shaft broke in the first place. That axle was doing what it was designed to do, basically the whole point of even having a full-floater. If the housing was bent, I would think we’d have seen a carrier bearing fail before the axle broke, not to mention there would be a noticeable difficulty getting the axle flange to line up with the hub studs.

Out of curiosity, it would be interesting to see the housing at least checked for straightness ..,

Is it possible the hub didn’t get fully seated on the seal surface after the bearing grease job? If there was a half inch of play there I could see that as a cause for the whole fiasco.
 
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I really don't think I got screwed on the axle housing, I wonder how a toyota housing is made?
Let me reword this! I want to remove SCREWED! If this was my company and rely entirely on my my word and the strength of my product, I would personally investigate this myself to ensure that my housing was'nt bent or improperly set in the fixture and welded incorrectly(seen it a million times.) Or a worn out fixture. I would KISS 😘 the customers 🐷s Arse until they would be satisfied. Thats how small businesses survive. Brain hurts 🧠🤯😴😴😴
 
Fixture??????
Most of the big guys will use a weld fixture, it’s what they do after welding that separates them. We can all agree that it's not possible to weld something like a spring perch on one side of a tube and not warp it to some degree. Pre heat and post heat along with a stout fixture will all help minimize but you should always check for straightness after it’s removed from the fixture and the pro shops that I know of will all do that.

These guys build stuff for rock crawlers or desert guys and those trucks are lucky to get 500 miles in a lifetime and Ron puts many times that in a single trip, a slight housing misalignment that makes zero difference on one rig could have catastrophic consequences on another. I’ve been around Ron a few times now and he’s not a complete idiot, I don’t buy a loose bearing started all this. For that bearing to be that loose for that long and Ron not notice a strange noise or feeling doesn’t sound like the attention to detail Ron we all know.

I’m not pretending to know what happened here and it all very well could be part failure or lack of maintenance but I would make damn sure I went over this entire assembly with a very critical eye before I put it all back together and headed out of town.
 
Yeah, I’d never insinuate that Ron doesn’t know what he’s doing, or that he’s an idiot.
I’m looking at 7 years and 49,500 miles of no issues, and then a couple of maintenance procedures and a locker change, and then 500 miles later there’s a catastrophe. It’s just what I’m seeing. I would absolutely hope to be wrong.
 
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