Sheared axle housing - Defender Source
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  #1  
Old March 20th, 2011, 04:30 AM
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Sheared axle housing

Ever seen an axle tube shear in half? You have now.

http://www.flickr.com/photos/defender90/5542417274/

Check out the map by the photo and you'll get an idea of how my day went.
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  #2  
Old March 20th, 2011, 10:59 AM
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An on-board welder would have probably been cheaper than the tow truck bill.
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  #3  
Old March 20th, 2011, 11:17 AM
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Yeah, a Power Welder is definitely on my list. Also going to start carrying a jack stand or two and an air-driven grinder.

USAA paid all but $200 of the tow.
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  #4  
Old March 20th, 2011, 02:25 PM
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wow.. were you wheelin' or just driving on the road when it gave way?
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  #5  
Old March 20th, 2011, 02:28 PM
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Scary....Details please!
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  #6  
Old March 20th, 2011, 02:40 PM
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Quote:
Originally Posted by chris snell View Post
Ever seen an axle tube shear in half? You have now.

http://www.flickr.com/photos/defender90/5542417274/

Check out the map by the photo and you'll get an idea of how my day went.
Yes.

Congrats on this though.
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Made it further than half of the other guys, but the Hammers won.
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  #7  
Old March 20th, 2011, 03:40 PM
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Quote:
Originally Posted by chris snell View Post
Yeah, a Power Welder is definitely on my list. Also going to start carrying a jack stand or two and an air-driven grinder.

USAA paid all but $200 of the tow.
How will you spin your air-driven grinder? Co2?

You need a York pump on your 90.
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  #8  
Old March 20th, 2011, 08:05 PM
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Quote:
Originally Posted by Buckon37s View Post
Yes.
Would you feel confident in a re-welded tube? I haven't pulled it apart yet but I'm guessing that the original weld just didn't penetrate well. The truck has very little rust. My biggest concern is that the other side of the tube may have the same defects.
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  #9  
Old March 20th, 2011, 09:10 PM
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I would get a Disco 1 rearend and use that. Cheap and readily available
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  #10  
Old March 20th, 2011, 09:30 PM
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I have purchased a D1 axle in the past, complete for $150.
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  #11  
Old March 20th, 2011, 09:34 PM
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I have seen such carnage while working on heavy over the road tractor trailers, spring perches come loose and the normal turning under load wears on the housing and it breaks... 3 or 4 times, but it is my first time seeing it on a light duty vehicle.
darn...
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  #12  
Old March 20th, 2011, 09:36 PM
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Like the others said time to buy a disco axle.

You should be able to get one for under $150. Place a wanted post on the Solihull site, call Keith @ rovertracks, craigslist and check car-part.com
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  #13  
Old March 20th, 2011, 10:00 PM
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There is no problem with welding that. Only challenge is getting it straight. Either way, welding it should get you through the week and get you home, even if it's not perfect.
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  #14  
Old March 20th, 2011, 10:30 PM
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Quote:
Originally Posted by chris snell View Post
Would you feel confident in a re-welded tube? I haven't pulled it apart yet but I'm guessing that the original weld just didn't penetrate well. The truck has very little rust. My biggest concern is that the other side of the tube may have the same defects.
I have done it before. If you were here I would do it for you. You can trench the crack and burn in. A small, simple truss will make it stronger than stock. Pretty simple. Or, like others have said, you can swap. Up to you. Good luck.
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Made it further than half of the other guys, but the Hammers won.
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  #15  
Old March 20th, 2011, 11:25 PM
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Thanks Buck, I appreciate the offer. Ben Little was with me when the tube broke and he suggested the truss, too. Says he's gonna do them for his truck.

Dan sees where I'm going with this. I'm not trying to cheapfuck out on replacing the tube; I just need to get the truck home safely from Moab to Colorado Springs and don't want a wheel coming off on Wolf Creek Pass. As soon as I get home, I'm pulling the entire assembly and the old tube is going in the trash.

On that note, this may be a 1 in 1000 freak occurrence but now that I have seen it happen to a very well-maintained truck on a pancake-smooth packed sand road, I don't doubt that it could happen again to someone else. I will have all of my rover housings trussed from now on. If this accident had occurred at higher speeds or on rougher terrain, I could have been a dead man.
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  #16  
Old March 20th, 2011, 11:58 PM
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Be sure to inspect the axle and make sure it did not bend.
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  #17  
Old March 21st, 2011, 12:32 AM
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Quote:
Originally Posted by chris snell View Post
Thanks Buck, I appreciate the offer. Ben Little was with me when the tube broke and he suggested the truss, too. Says he's gonna do them for his truck.

Dan sees where I'm going with this. I'm not trying to cheapfuck out on replacing the tube; I just need to get the truck home safely from Moab to Colorado Springs and don't want a wheel coming off on Wolf Creek Pass. As soon as I get home, I'm pulling the entire assembly and the old tube is going in the trash.

On that note, this may be a 1 in 1000 freak occurrence but now that I have seen it happen to a very well-maintained truck on a pancake-smooth packed sand road, I don't doubt that it could happen again to someone else. I will have all of my rover housings trussed from now on. If this accident had occurred at higher speeds or on rougher terrain, I could have been a dead man.
If you can get ahold of a good welder, you can burn it in with a straight-edge. It wont be perfect, but it will get you home without issue. I broke my front-end in half completely in glamis and bribed a tow truck driver to let me use his welder while he looked the other way. It got me home without issue. Later I squared it up (it was shockingly close) and trussed it. Welds can fatigue over time, and the axle's OD is really too small for the weight over it. I am surprised it does not happen more often. Good luck!
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Made it further than half of the other guys, but the Hammers won.
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  #18  
Old March 21st, 2011, 01:22 PM
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Update: it was a bad weld from the factory. Poor penetration and it pulled cleanly in half as though sawed. I have a guy welding it back together for me. It has been resting on the RoverTracks axle and brake caliper. I'm going to throw a stock halfshaft back in it for the drive home.

Check your axle tube welds! I will never blindly trust another rover axle tube.
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  #19  
Old March 22nd, 2011, 11:13 PM
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http://www.flickr.com/photos/defende...7626204989387/

http://www.flickr.com/photos/defende...7626204989387/
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