I snapped my driver's side axle at the 3rd Annual Shocker Run at the end of the day. Lucky for me, it was a clean snap and it broke off at the splines going into the diff.
I snapped it climbing this concrete hill on Rausch Creek's Comp Course.
Here is the video of it happening. The truck starting hopping and that was all it took to snap it.
http://gallery.me.com/brandonkennedy#100008/Cv%20snap&bgcolor=black
We removed the broken half shaft right after I broke it and I drove home with only 2WD.
This past weekend, acting on the advice of BklynX, XterraVT and XVTer I safely and successfully removed the broken piece of axle and replaced the half shaft with a new (used) one. Dave XterraVT was in town to help me.
The steps to remove the broken piece:
- Jack up the truck and support with a jack stand
- Remove tire, loosen UCA/Spindle and undo coilover shock.
- Drill into the broken axle piece.
- Tap the hole with threads.
- Screw a bolt into the threaded hole.
- Apply pressure and remove the broken piece.
- Clean Diff opening with magnetic retractor.
- Replace Axle Shaft with new one.
- Replace front Diff fluid and check Diff drain plug for metal shavings or debris. (Fluid is 75W-90 synthetic gear oil in the R180)
Broken axle shaft.[/b]
Step 1. Using a 1/4" drill bit, drill into the center of the broken piece of axle shaft. You will need a 6" long drill but to reach the broken piece without hit the frame or bump stop mount. Do NOT drill through the broken piece! Use the remaining axle shaft to gauge how deep to drill. I suggest no more than an inch.
Drilling into the broken piece.
2. Tap the hole you drilled with a 1.25 thread pitch, 5/16" tap.
Tap slowly and do not force this step. You may have to tap a quarter turn and then reverse the tap before moving forward again. This is will assure you do not get the tap stuck in the hole
5/16" Tap and 5/16" bolt to screw into broken axle piece.
Threading the hole with the tap.
3. Clean the area of debris, such as metal shards or large pieces of axle shaft.
Axle shards from the drilling.
4. Thread the bolt with a large washer into the tapped hole and apply pressure both outward and upward to remove the broken piece. Do not rush this step. Slow and steady is the way to make this work.
I used a pair of vice grips and a pry bar to finally get the bolt out. The double pressure was need to release the C-clip at the end of the broken axle shaft.
Success!
The culprit of my troubles.
Two pieces reunited again.
Clean brake leaves diff intact.
Side by side comparison.
I also purchased a new 32mm axle nut and new cotter pins for both sides. The broken half shaft was used and had a 36mm axle nut, which does not match the OEM specs.
Old 36mm half axle shaft nut.
New nut and appropriate 32mm axle nut socket.
6. Remove diff plug and drain diff. Check drain plug for metal shavings. Replace plug and refill with 1 quart of 75W-90 synthetic gear oil for the R180 Diff.
A very special thanks to Dave, XterraVT, for helping me out with this repair. I definitely recommend having two people for this repair, as it makes the hole process quite easier.
