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Old 05-21-2007, 06:29 PM
Dan-H Dan-H is offline
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how to extract a broken axle shaft stuck in the ARB?

I broke my passenger inner axle (long side) at or near the splines yesterday, and a few inches of the shaft was stuck in the carrier (ARB).

The break was pretty clean. I pulled the diff cover and found no metal pieces.

The only option we could think of (given the tools we had on hand) to get the broken piece of axle out of the ARB was to remove the driver side shaft and push the broken piece through, and then fish it out with an antenna or something the rest of the way.

Other than removing the driver side shaft and pushing the broken piece through, is there a trick or technique to get the broken end of the inner axle out?

Now that its home is there any other maintence I should consider?

I'm planning replacing both sides with new assemblies and planning to install new unit bearings. I'll keep my current ones for spares.

btw, the Ujoint survived the initial axle break, but snapped when I was being winched out backwards, or while backing into a suitable spot for repairs.

ps: I know the consensus is that stock shafts and unit bearings are not up to 35s, but at this point in time significant upgrades are not in the game plan. I have all the parts except for the unit bearings, and the only parts that are toast are the long inner and the Ujoint.
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Old 05-21-2007, 08:53 PM
NAILER341 NAILER341 is offline
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it sounds like you have the right idea. you'll just have to find something narrow enough to squeeze by the pin.

i suggest opening it up after you get the piece out of there, and check the locker for damage.

this is especially so, if it was an alloy axle shaft that broke in there.
good luck!
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Old 05-21-2007, 09:25 PM
Dan-H Dan-H is offline
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factory shaft.
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Old 05-21-2007, 11:16 PM
Jeff Weston Jeff Weston is offline
Can I get a mint julep with that?
 
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Dan,

If that shaft is wedged in there anything like mine was, you'll have to remove the other shaft and beat it out. Like Erik said, you'll need something skinny that can squeeze by the cross shaft in the locker.
Blaine 'fabricated' a broken axle shaft removal tool on the trail with a flat screwdriver and a blow with a hammer. After attaching all of our extensions together and sticking the screwdriver in the end, he banged the holy hell out of it and it shot out of the other end like a cannon. Make sure nobody is on the other side as you do this.

Good luck!
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Old 05-22-2007, 06:58 AM
Dan-H Dan-H is offline
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Thanks for the tip Jeff. I haven't torn into it yet.

Also, to clarify my original post, I chose not to take apart the driver side on the trail. I pulled the diff cover and found no metal shavings or chuncks.

The day was getting late, and the driver side was in a really muddy / snowy spot. I picked a semi dry spot to work on the passenger side, but didn't think about having to pull the driver side.

3 wheel drive was enough to get out and I had rigs in front and behind me if I needed help.

I'll report back how easy/hard it is to do. Part of this is to make sure I've got all the tools I need to fix it if it happens again.
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Old 05-23-2007, 02:45 PM
Iceman Iceman is offline
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as Jeff mentioned -> I've still got the 'Blaine special' screwdriver-that-I-don't-like for that exact purpose. Just make sure you've got enough length (on the trail with socket extensions) to get to the axle stubby that's still in there
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Old 05-23-2007, 03:09 PM
Dan-H Dan-H is offline
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I just thought of another thing that might work.

the OEM jack extension that spins the bottle jack.

I was probably sitting on it when we were brainstorming how we'd get it out...

I won't get to work on this for a few days but I'll see if that would work.
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Old 05-23-2007, 04:33 PM
Kiwi Kiwi is offline
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Quote:
Originally posted by Iceman
as Jeff mentioned -> I've still got the 'Blaine special' screwdriver-that-I-don't-like for that exact purpose. Just make sure you've got enough length (on the trail with socket extensions) to get to the axle stubby that's still in there
And don't forget to duct tape ALL the extensions together
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Old 05-23-2007, 05:38 PM
mrblaine mrblaine is offline
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Quote:
Originally posted by Dan-H
I just thought of another thing that might work.

the OEM jack extension that spins the bottle jack.

I was probably sitting on it when we were brainstorming how we'd get it out...

I won't get to work on this for a few days but I'll see if that would work.
We tried it. The hook on the end is too big to slip past the crosspin.
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