Rear TRD Axle Shaft Brakage

[SD4runner]

I had posted this up on TOF, but would like to post here as well just for future reference. I haven't heard much of this happening before.

I found it quite interesting that the stock axle shafts were fragile enough to break on the hi-way, especially in the middle of Baja. Which sucks.

Apparently, they broke right at the C-clip grove which holds the bearing retainer. Makes sense since that is the narrowest part of the axle shaft...

So right now I am planning on buying an axle assy and driving back down to repair. My backing plate, bearing container, bearing retaining ring, etc were all damaged. My rear drivers side wheel passed me at about 40 mph and I dropped violently to the pavement and slid a good 50-100 yards before I gained control to pull off the highway.

Luckily, the people there are genuine and giving enough to offer me a place to keep my truck, and as well offered me a place to stay.

I ended up taking the bus back to Tijuana and walked across the border at 11pm to be picked up. It was certainly a journey! :D

Here's some pics of the breakdown:
http://img.photobucket.com/albums/v346/sc4runner/DSC04713.jpg
http://img.photobucket.com/albums/v346/sc4runner/DSC04706.jpg
http://img.photobucket.com/albums/v346/sc4runner/DSC04721.jpg
http://img.photobucket.com/albums/v346/sc4runner/DSC04704.jpg
http://img.photobucket.com/albums/v346/sc4runner/DSC04736.jpg

We had a good trip though...
http://img.photobucket.com/albums/v346/sc4runner/DSC04677.jpg

[Lee]

wow, never heard of this happening! :yikes:

[Seanz0rz]

was reading this on TOF, scary!

you should be able to replace it with a whole assembly, i know toyota doesnt offer the assembly, but buy one from someone parting out if you have the time

[Cheese]

I have never seen a rear break there.

It is smaller diameter at the inner parts of the splines.

Usually rears flex, bend and snap nearer the third. I suspect something else was going on.

Glad you are safe.

[mastacox]

Is this a fatigue failure due to increased load on the shaft from oversize tires/lift and agressive offroading?

[sschaefer3]

I have never seen a rear break there.

Yes you have. When Stubbs rolled the buggy down Hells Gate.

My 4Runner & Rock Buggy have the ones from Poly Performance, there is a huge difference in those versus a stock axle. Huge Difference.

http://www.polyperformance.com/shop/1995.5-2004-Tacoma-Rear-Axle-Shafts-p-778.html

Tacoma axles fit the 96-02 4Runner tube.

[alpha_nett]

that sucks man! i was down in baja last year for the 1000. going again this year. i am getting extra parts prepared already, but i never would have thought to bring rear axle stuff.
hope your truck is ok down there!

[sschaefer3]

Also remember that each side is different.

[Cheese]

I think that rollover breaks from leverage are a little different. I have seen one shaft break here and that truck went over twice hard. I will ring you Thursday.

I have 4340 axles from Poly.

Usually, as I understand, the outside at the wheel has more play up and down than at the diff, so it bends the shaft and snaps it.

Have any of the splines deflected?

[mastacox]

The closeup of the shaft's failure point shows classic signs of a bending fatigue failure. Perhaps the bearing was a little old and not supporting the shaft as stiffly as intended?

SD's picture:
http://img.photobucket.com/albums/v346/sc4runner/DSC04713.jpg

Bending Fatigue Examples:
http://www.msm.cam.ac.uk/phase-trans/2006/SI/9.jpg
http://www.testlabs.ca/images/casehistory2.gif
http://www.corrosionlab.com/Failure-Analysis-Studies/Failure-Analysis-Images/28186.mechanical-fatigue.ss-bolts/figure02-beachmarks.jpg

[SD4runner]

After I get the truck back into the states, my next investment will most likely be the poly performance shafts. I'm assuming you'll need new bearings and other parts when replacing just the axles?

Anyways, DeathCougar has helped me out and is sending down an axle shaft assembly for me. The junkyards around here were sketchy and I couldn't find anything that matched my application exactly. Finding a towing company to bring it across the border is becoming more difficult, and I have no access to a large towing capable truck to bring it up myself.

I have done some pretty good offroading this past year (after about a 2 year hiatus of living in Santa Cruz)... It must have caused a weak point in the axle shaft and the long 1000 mile drive into Baja must have caused it to snap.

It was very scary, and I really hope it doesn't happen again or to anyone else. I was lucky I was only going 40 mph and not 70 and roll my truck or have my car or tire hit someone else...

As for the inner splines (I never removed the parts to look at the outer splines as I thought they were fine)... The inner splines were in perfect condition. Is this enough information for me to rule out further dmage to the ring and pinion?

The bearing also appears to look really good. No weird fractures or wear on it. Who knows.

[Cheese]

Had you done axle work lately?

That is not from wheeling. It is like the backing plate was loose and started walking out or something.

[SD4runner]

Nope. I had replaced the axle seal probably close to two years ago. The 4 nuts that hold the backing plate/axle in the housing were tight as could be!!

Ugh. Well I really have no clue then what would have caused it. I mean, I was coasting a long, and *snap* then I shimmied back and forth as I slowed down, then the wheel came off. WTF! :(

[neliconcept]

just looking at this, im going PP axle shafts soon as I have extra income.

[SD4runner]

Welp, its almost been a week...

I got the axle shaft assembly from Death Cougar (awesome) in the mail, so tomorrow morning I'm driving back down and doing the repair. I hope everything works out well...

...and my truck is still there...

[Seanz0rz]

good luck man. do you have contact info from some people on here to call if you need help while down there? might be a good idea.

[slosurfer]

Good luck, hope it all turns out okay. :thumbup:

[YotaFun]

Good Luck,
Hope your truck is still there and all works out well and you get home safe :-D

[SD4runner]

Reporting back!

I arrived yesterday afternoon to find my truck stripped and upside down...

Just kidding.

The truck hadn't been touched, I was almost suprised. What was even more suprising is that I fixed it in the dirt, ticks and hot sun in only a few hours and was on my way. Woo hoo. ;)

I gave the family some food and wine... but, they strongly rejected to take the $500 pesos ($50). The man actually got mad for me actually offering it to him. I told him in spanish..."This is for your home, for your family, thank you for keeping my car safe!!". He said that he would not accept it because it wasn't "work" for him. Amazing people. I came back and told him it was part of my culture to pay for everything, and he smiled and said its my culture to only be paid for work. ;)

[slosurfer]

:clap: That's awesome! Glad it all got worked out. :thumbup: