Cruzer's Re-Build for the Rubicon

When I recently busted the CV axle I found myself running around like a headless chicken wasting time looking for the tools I needed to replace it. My friend was like “I thought you could swap out an axle in less than 30 minutes?”

I decided I needed a dedicated toolset all in one place so I got a pouch for all the small tools.

 

Awesome!
I'll bring the torque wrench.

 

Are the two extra bolts for the lbj just in case?

 

They’re for the brake calipers

 

Is that a murse?

 

Hmm well check that out. Broke in a different spot than I thought, which is great cuz I don’t have to take out the driver CV axle glass half full I’d say.

 

Hey, what's up with this?

When I look at the "right" one, I see a difference in the metal, about the same place where the other one broke. Is that something to do with fabrication, or wear? (Something that's gonna happen again?)

 

good catch sunny

 

Didn’t notice, guess we’ll find out

 

Went through the garbage bin to fish these suckers out to get a better look. I'm not a metal guy. Does it look like it was once a solid shaft or was it welded together? @helidave @snivilous

 

Hmm interesting

 

Looks solid to me. Looks like a pretty classic shear failure. I'm not a metallurgist but the colors I wouldn't chalk up to much besides maybe darkening from high stresses. The outer cracking is probably due to the OD having the highest strain and once it fracture strain and couldn't stretch any more it let go and then the rest of the shaft too. The look of the surfaces and the sphincter look pretty standard for a sheared shaft.

If you search shaft shear failure there's some pictures that look very similar with the discoloration, surface condition, and the axis of twist.

This website shows a similar picture:

https://cr4.globalspec.com/thread/12259/Failure-Analysis-of-agitator-shaft

 

Dropping that knowledge!

 

Shit... I'm a pilot, not a scientist. Looks broken to me

 

It looks like a multiple origin failure due to overloading. Nothing out of the ordinary. This diagram may help to understand this type of failure.

 

Is the "difference in the metal" you see the color?

 

I'm sorry; I don't understand what you're asking. I used a green coloured marker to encircle the portion of the axle where I perceive the metal is lighter in colour than the remainder of the axle. Whatever the cause, the metal appears "lighter" to me, and in the same area of axle where the other axle broke.

 

I was trying to understand if the color of the metal is what you were talking about. Which you have clarified.
I will say in this case it is simply a color, and has no bearing on the breakage or breakage points. To simplify the manufacturing process on that part, that shaft is machined and then heat treated. The heat treat is likely where it got that dark color. After heat treat it is ground on specified surfaces. (Those are the shiny surfaces). That's why the "colors" are the way they are.

 

Thank you for the info.

 

Hmmmmm you seem to know quite a bit.. do you happen to know of any shops, since you're in NorCal, that can replicate this shaft in a stronger alloy?

 

Used to have an old millwright that retired and opened up a machine shop as a hobby. That dude could build anything out of metal. He has passed but I am sure you could find someone in your area that could make one out of some kind of billet material.

 

Maybe hit up spidertrax?

 

I guess it won’t hurt to ask them. Wasn’t aware they made anything else other than spacers.

 

Broooo they build the premier off-road axles. Wheel spacers are just what the mall community knows them for. Probably the majority of buggies you see with fabricated axles are spidertrax stuff. All custom from the housings to the axle shafts to the unit bearings and made inhouse. Chromoly, 300M, full float, custom brakes, etc. They build some of the fanciest parts in all of off-road.

 

The problem with getting something custom made is the price. There are shops all over norcal that have the capabilities, but you will pay a ridiculous amount to get one or two made.

 

Yup.

 

Picked up a transfer case today.

 

did you need a new one? or is it a spare....

 

For parts and to help create an adapter for the Atlas transfer case.

 

What do you think our backup plans should be if trails remain closed?