WEIRD rear axel break....

[chicago]

So, I busted my FIRST EVER axel this past weekend.
I lucked out in SOOOOO MANY ways, I cant even tell you all here...
So I wheeled the Wentworth springs loop on the Rubicon. AWESOME...Not a lick of trouble all day and the rig performed flawlessly.
We get back out on the pavement leaving Loon Lake, and my DS rear axel gives way about 2 miles out.
We stop, jack up the rig, pull the rest out and it broke off at the c-clip groove. Everyone was puzzled by this including myself as I had never seen that one before...
Has anyone ever had this happen, or SEEN this happen.
Im running stock rears with a lock right, and 230K on said axels.... The general concensus around the camp fire was that it was the locker that was the culprit.
Is that true? was it a fluke/ old age?
What is the next step in prevention from this happening again.

Ill post pics later to make this clearer.

Id like to post a HUGE THANKS to the mudders/ Norcal Wagons guyz for stepping up to help out on this fantastic repair, especially Diesel Bigot and his wife for driving 2 hours EACH WAY to get my dumb ass an axel, Cruiserdrew for helping/ doing the repair and RustyTLC for hangin out, hauling my gear and helping distribute needed items while we were under the rig.

BTW...I need a long side rear to return to Diesel Bigot. All he asked was to replace it...that was it...no money, no nothing!
What an OUTSTANDING COMMUNITY!
So, with that being said...PM me if you have a set that you could spare!

Thanks,

Chicago

 

[LCOwner]

Is the long side the most common to go? Seems odd to me if it is. But you said you broke it at the clip groove so I guess it's not the norm.

 

[Mace]

I have heard of it once. 2bad had it happen to him.

Other than that, nope..

 

[Dirtgypsy]

Did it pop at the c-clip from the locker loading and unloading?

Maybe it's just me but nothing suprises me any more.

Clint

 

[cruiser88]

I am with the old age and locker combo

 

[Mace]

I would be willing to bet it was more an issue with a worn C clip allowing some movement in and out with the axle shaft.

the locker should not put any more side load on the C clip than an open diff does. Unless it was machined improperly and allowed the axle to move back and forth.. Which I kinda doubt. The C clip would have a tendency to walk out then..

 

[rusty_tlc]

I am with the old age and locker combo

What is puzzling is that the splines were in perfect condition, it broke off in the c-clip groove. Actually most of the groove is intact, it snapped off just the smooth part that is closest to the end of the axle. If it was from shock loading the axle I'd expect it to fracture where it was getting loaded not the free end that just floats inside the diff. I saved the piece that broke off and will post a picture when I get my truck back. It's on loan for the next couple of days.

I've been wondering if a FF axle would have saved much work. AFAICS we might have been able to pull the other axle and rear DS so Keith could get back to camp, but I'm not sure I would want to drive too far like that. Definatly not over the Sierra.

BTW Chicago way understated my part in the repair, I also heckled the guys doing actual work and pointed out trucks full of pretty girls just after they had passed. Wait, I never did get around to mentioning the truckloads of pretty girls, sorry guys.

 

[Mace]

Its a sideloading thing, not shockload..

 

[wngrog]

I broke one just like that on an Fj40 once......but then, I have broken Cruiser axles in ever spot they can break :laughing:

 

[rusty_tlc]

I would be willing to bet it was more an issue with a worn C clip allowing some movement in and out with the axle shaft.

the locker should not put any more side load on the C clip than an open diff does. Unless it was machined improperly and allowed the axle to move back and forth.. Which I kinda doubt. The C clip would have a tendency to walk out then..

We put the old c-clip back in

I guess we get to open up Keith's Lockrite again.

The lesson I learned from this, well actually from this and not knowing how to get my FJ40's ARB apart on the trail last summer, is that I will at the minimum get the install instructions for my FJ60 Detroit lockers and keep them in the rig. Ideally I will pull the rear axles and replace the oils seals just to have some hands on experience. The toughest part of the whole day was noodling out how to get things apart and back together.

 

[rusty_tlc]

Its a sideloading thing, not shockload..

thats what I was saying...

 

[Cruiserdrew]

I still think it's related in some weird way to the Lock Right. That's a pretty funky way of retaining the c-clips with that secondary inner cup holding the works together.

I got home and looked it up, we did re-assemble it correctly, even if uneducated. the only thing we did not in the instructions is we didn't coat everything with grease to hold it together while doing the assembly. I'd just run it as is, carry a spare and now the knowledge of how to put it together.

BTW-That tool I made to inset the pins, is EXACTLY what they show in the instructions I found on line. Too funny. I'd keep that bent up cotter pin for the next time and as a reminder of a great day at Loon Lake!

The only reason I'd go back in that diff, would be to replace the stock axles with polys. Otherwise, I'm confident we did it right.

I have only 1 spare 60 inner(and 3 trucks that use that as a spare, or I'd offer up a replacement for Brett.

Kieth-probably time for a set of Polys or a different locker or both if the $$ cooperate.

Very fun weekend.

 

[Mace]

Long side Cruiser shafts are getting tougher and tougher to find....

 

[slcfj62]

Is the broken part all the same color? Does it look like it broke all at once, or maybe cracked over time and finally the last bit let go. That would sure be bad news on a skinny trail with a cliff on one side.

 

[rusty_tlc]

Long side Cruiser shafts are getting tougher and tougher to find....

Legend has it there is a cruiser grave yard locate in a secret location just east of here. I'm betting he already made the call.

 

[rockclmbr]

Hey Keith, glad you were able to button it up and get home!

Was the original c-clip deformed at all? Was it still in the original place or did it fall out with the gear oil?

I think it had to be a high lateral load that caused the failure. With that many miles on a hard core wheeler, there is a possibility.

 

[cruiser88]

How was the thrust washers.....loose, worn.. maybe?

 

[Trapper50cal]

Perfect time for some polyperformance 4340's and an Aussie...

 

[Mace]

How was the thrust washers.....loose, worn.. maybe?

Were, Were the thrust washers.....

never mind..


Crazy has a point..

The Aussie relies on a certain amount of "play". It's possible that a excessive amount of play in the thrust washers would allow the axle the movement that is necessary to blow the C clip groove out.. The problem I see with this is that the locker would slip a LOT, and potentially not engage.. IT is something to keep in mind tho..

The center pin in a lunch box locker forces the inner quarters, into the outer quarters. The C clip is not really "hit" by anything but the pin, so it should not be an issue. but if the outer quarters have a significant amount of play, I suppose it is possible for the C clip to be "worked" back and forth...

Interesting..

 

[cruiser88]

lol..... You come right to the point.....crazy sometimes talks in circles

Were, Were the thrust washers.....

never mind..


Crazy has a point..

The Aussie relies on a certain amount of "play". It's possible that a excessive amount of play in the thrust washers would allow the axle the movement that is necessary to blow the C clip groove out.. The problem I see with this is that the locker would slip a LOT, and potentially not engage.. IT is something to keep in mind tho..

The center pin in a lunch box locker forces the inner quarters, into the outer quarters. The C clip is not really "hit" by anything but the pin, so it should not be an issue. but if the outer quarters have a significant amount of play, I suppose it is possible for the C clip to be "worked" back and forth...

Interesting..