Snapped Axle

[BReNt]

This happened to my dad once and from memory he welded a bolt onto the broken bit of axle that he couldn't get out, then put a puller on the bolt and got it out that way.

[Mick E]

well I would call that the spider gear support shaft but thats just me and yes I wasnt thinking at the time as know all about that one (snapped in my wagon)

redwarf is right most axles snap at spline should be able to remove diff centre

[Mick E]

As title suggests I've snapped an axle in my KE30, the part of it that fits into diff still remains inside(stopping me from removing my diff :) )

 

Any suggestions to getting it out(preferably without removing diff housing)?

 

And if too much hassle would I be alright chopping part of the affected axle off so only one wheel spins, but so I can still bolt it back up(have a welded diff)?

 

Or if possible to remove the stuck part of axle, mine being a banjo type, would a borg warner axle fit(as these are much easier to find for me)?

 

Few questions but any suggestions/ experience will be much appreciated.

 

Cheers

most axles snap at spline end should be able to remove diff centre

[1975ke30]

most axles snap at spline end should be able to remove diff centre

 

Yes it did snap at spline end but there was just enough left to stop me from removing diff centre without removing the whole housing aswell, may have been because I drove it home about 7 kms or so because when I did bang the whole housing on the ground(as explained by Rolliac), part of the axle fell out(thus allowing diff centre to be removed), but still some of the spline remained.

 

Brent that's an excellent idea, ill try self tapping a bolt(as I have no welder/welding skills) into the left over spline and using a puller to remove.

 

Cheers guys your abundant ideas/knowledge is the exact reason this is the place I search when I have any problems with my Rolla.

[Redwarf]

I use a long, thin diameter pin punch from the other side. You can usually get it past the shaft in the middle of the diff if you try hard enough.

[altezzaclub]

Hmm.... "I was smashing pretty hard"

 

That doesn't sound good... There may be damage to the diff splines that the axle fits into. Check it carefully as it may be a throwaway anyway. If the splines get worn to a skinny point they will not last.

 

Welding the diff up means those splines take a tremendous amount of abuse.

[philbey]

exactly, that chirp chirp chirp as you corner is constantly loading/unloading the axle on the inside, quite violently. Splines are an engineering conundrum, they're really good for power transmission but the sharp corners create stress risers which magnify the stress and reduce the number of "ups and downs" before failure.

[1975ke30]

I use a long, thin diameter pin punch from the other side. You can usually get it past the shaft in the middle of the diff if you try hard enough.

 

Mate you are a f@$king legend, this worked perfectly. I presumed the shaft would be in the way but there was just enough room.

 

Diff splines look alright, CRC'd and can't see bare metal or any inconsistency with other one so presuming/hoping they're fine.

 

Thanks to all for putting forward your ideas/experiences, Rollaclub saves the day once again!