12-22-2021, 06:44 PM
|
#1
|
|
Member
|
|
Join Date: Nov 2017
Location: Orlando
Posts: 74
|
|
Member
Join Date: Nov 2017
Location: Orlando
Posts: 74
|
Slightly mushroomed Axle shaft splines... how to fix?
So, I recently took my axle shafts out and had a shop remove bearings, ABS tone-loc ring, etc. and press the new parts back in.
I was just putting them back in, and one side went together no problem.
The side he said he had the toughest time with would NOT finish going in. They go in almost all the way to the pumpkin, but it won't go the rest of the way. I pulled the shaft and examined the splines and they are just, EVER so slightly mushroomed.
I ordered some hand files, I have access to just about anything else I might need to grind or cut.
What would you guys recommend and is there any unforseen danger in doing this?
Picture attached:
geojson file viewer
__________________
2001 4Runner 4x2 Sport Package
2009 VW GTI (To many things to list)
|
|
Reply With Quote
|
12-23-2021, 11:11 AM
|
#2
|
Junior Member
|
|
Join Date: Jan 2020
Location: Alberta
Posts: 25
|
|
Junior Member
Join Date: Jan 2020
Location: Alberta
Posts: 25
|
1st option: Have a word with the shop. There's a strong possibility they beat the end of the axle with a hammer to disassemble the shaft assembly. Check for possible denting from a hammer on the shaft's end to confirm. There are much more refined ways to do that...
2nd option: Replace the mushroomed axle with a used one from a junk yard or wherever else you can source one. I would say filing the axle down to fit is possible, but the risk of wearing the splines in the mated side gear would sit in the back of my mind.
3rd option: File the axle spines as you have mentioned. Its a bit tough to read, and I would prefer to compare to the axle on the other side, but witness marks on the splines seem to say that the last 1/4" of splines are not engaged in the side gear (therefore, not loaded). If the last 1/4" are not engaged in the splines of the side gear, then filing would do no harm. If you do file, keep in mind that you will have to remove material from the tip AND root of the splines. Remove as little as possible.
This is just my best opinion on this. Splines generally aren't serviceable, but in this case you likely could get away with it. If you remove too much of the splines in an engaged area by getting carried away, you might introduce uneven loading on the splines resulting in fatigue cracks or fretting. Not to mention you may interfere with any surface level heat treatments. Hope this helps.
|
|
Reply With Quote
|
12-23-2021, 11:29 AM
|
#3
|
|
Member
|
|
Join Date: Nov 2017
Location: Orlando
Posts: 74
|
|
Member
Join Date: Nov 2017
Location: Orlando
Posts: 74
|
Quote:
Originally Posted by jlaho
1st option: Have a word with the shop. There's a strong possibility they beat the end of the axle with a hammer to disassemble the shaft assembly. Check for possible denting from a hammer on the shaft's end to confirm. There are much more refined ways to do that...
2nd option: Replace the mushroomed axle with a used one from a junk yard or wherever else you can source one. I would say filing the axle down to fit is possible, but the risk of wearing the splines in the mated side gear would sit in the back of my mind.
3rd option: File the axle spines as you have mentioned. Its a bit tough to read, and I would prefer to compare to the axle on the other side, but witness marks on the splines seem to say that the last 1/4" of splines are not engaged in the side gear (therefore, not loaded). If the last 1/4" are not engaged in the splines of the side gear, then filing would do no harm. If you do file, keep in mind that you will have to remove material from the tip AND root of the splines. Remove as little as possible.
This is just my best opinion on this. Splines generally aren't serviceable, but in this case you likely could get away with it. If you remove too much of the splines in an engaged area by getting carried away, you might introduce uneven loading on the splines resulting in fatigue cracks or fretting. Not to mention you may interfere with any surface level heat treatments. Hope this helps.
|
Thanks for the response! I got a hell of a deal using the shop, so I'm loathe to take it back and make a big deal out of it, especially if I can correct it here with a little bit of work.
If it's truly borked I'll take it back, but there aren't many shops that would have done both axles for what I paid in as short a period as they did, especially with me bringing them the Axles.
I'll carefully file it down here and see if I can't get enough clearance to get it to at least get through that last bit. I'm pretty much with you on thinking it shouldn't be a big deal, but I figured I'd check first before I go and jack it up any more.
So, a little more sweat equity here, I'm ok with that, lol
__________________
2001 4Runner 4x2 Sport Package
2009 VW GTI (To many things to list)
|
|
Reply With Quote
|
12-23-2021, 11:32 AM
|
#4
|
Junior Member
|
|
Join Date: Jan 2020
Location: Alberta
Posts: 25
|
|
Junior Member
Join Date: Jan 2020
Location: Alberta
Posts: 25
|
Good deal! Give us all an update on how it goes? Oddball issues like these are neat to follow.
|
|
Reply With Quote
|
12-23-2021, 02:01 PM
|
#5
|
|
Senior Member
|
|
Join Date: Mar 2010
Location: denver
Posts: 3,010
|
|
Senior Member
Join Date: Mar 2010
Location: denver
Posts: 3,010
|
Quote:
Originally Posted by jlaho
Good deal! Give us all an update on how it goes? Oddball issues like these are neat to follow.
|
Filing the grooves down should work.
|
|
Reply With Quote
|
12-23-2021, 02:47 PM
|
#6
|
Member
|
|
Join Date: Feb 2021
Location: America
Posts: 86
|
|
Member
Join Date: Feb 2021
Location: America
Posts: 86
|
I like how you use the term ever so slightly. I would get a new shaft instead of screwing around filing it. It’s already screwed and filing it will just remove material and cause more damage. Don’t listen to anyone telling you to file the splines. Get a new or used shaft
Last edited by bmason8159; 12-23-2021 at 02:50 PM.
|
|
Reply With Quote
|
12-23-2021, 06:34 PM
|
#7
|
|
Elite Member
|
|
Join Date: Feb 2015
Location: San Jose, California
Age: 58
Posts: 5,278
Real Name: Tim
|
|
Elite Member
Join Date: Feb 2015
Location: San Jose, California
Age: 58
Posts: 5,278
Real Name: Tim
|
I would get the shop to own their screw-up and buy you a replacement axle shaft, and bearing. The tone rings and ABS sensors can be saved if they pull the parts off rather then cut them off but the bearing will take a load when you press the axle out and no way would I reuse that bearing.
After that, I would never use them again. I'd do the job myself or take it to another shop that knows what they are doing.
__________________
"My old man is a television repairman, he's got this ultimate set of tools. I can fix it!"
|
|
Reply With Quote
|
12-23-2021, 07:48 PM
|
#8
|
|
Member
|
|
Join Date: Sep 2021
Location: Fayetteville AR
Posts: 776
|
|
Member
Join Date: Sep 2021
Location: Fayetteville AR
Posts: 776
|
Quote:
Originally Posted by FiXXXerX
So, I recently took my axle shafts out and had a shop remove bearings, ABS tone-loc ring, etc. and press the new parts back in.
I was just putting them back in, and one side went together no problem.
The side he said he had the toughest time with would NOT finish going in. They go in almost all the way to the pumpkin, but it won't go the rest of the way. I pulled the shaft and examined the splines and they are just, EVER so slightly mushroomed.
I ordered some hand files, I have access to just about anything else I might need to grind or cut.
What would you guys recommend and is there any unforseen danger in doing this?
Picture attached:
geojson file viewer
|
That shop screwed you up. Looks mushroomed on both the top of the grooves and the inner ruts of the grooves also. It doesn't look like it engages with the mating grooves on that last end area so it doesn't do work. You can do it if you're careful and don't damage the pumpkin splines if you didn't already trying to get it in. Calipers would be helpful.
|
|
Reply With Quote
|
12-24-2021, 01:13 PM
|
#9
|
|
Member
|
|
Join Date: Jan 2021
Location: Idaho
Posts: 610
|
|
Member
Join Date: Jan 2021
Location: Idaho
Posts: 610
|
That axle is toast. Looks like they didn’t know what they were doing.
__________________
99’ Black “Highlander” sport, oak, 5VZ auto, 4.30 axle, e-lock, 265/75 Grabber X3,, Bilstein 6112 (2”) front 5160 rear shocks, OME 2906 springs, Durobumps, 4x Inovations front middle rear skid plates, 4XI square TRD tube sliders, lil skips tank skid, lotus dev RCA skids, overland custom sway bar links, Amp’d hidden winch, warn Vr Evo 10s
|
|
Reply With Quote
|
12-24-2021, 01:25 PM
|
#10
|
|
Member
|
|
Join Date: Oct 2010
Location: High Country, CO
Posts: 609
|
|
Member
Join Date: Oct 2010
Location: High Country, CO
Posts: 609
|
File to fit. It'll be fine.
__________________
'97 SR5 V6 4x4 | 5-speed | e-locker | 33's
|
|
Reply With Quote
|
12-24-2021, 03:45 PM
|
#11
|
|
Member
|
|
Join Date: Aug 2019
Location: Fair Oaks, CA (Sacramento)
Posts: 255
|
|
Member
Join Date: Aug 2019
Location: Fair Oaks, CA (Sacramento)
Posts: 255
|
__________________
1997 Toyota 4Runner
|
|
Reply With Quote
|
12-24-2021, 08:01 PM
|
#12
|
|
Elite Member
|
|
Join Date: Jun 2011
Location: Shangrila
Posts: 5,037
|
|
Elite Member
Join Date: Jun 2011
Location: Shangrila
Posts: 5,037
|
You know what they say about the guy who can do the job cheaper... he does it cheap! The whole point of outsourcing that is because you expect him to have a press to properly do this.
This is a precision job. I'm reluctant to even trust most mechanics to do this at prices that seem fair with market rate. I doubt they will read all the little details of doing this job, or even have the proper press tool to do it. I would tell you to go back and get them to own up, but that will be difficult(especially if you paid cash). I guess it's worth a shot, but it will be awkward af. You are in need of a new bearing and axle shaft now. I guess you could file it, but what did you pay for then?
|
|
Reply With Quote
|
12-25-2021, 12:18 AM
|
#13
|
Senior Member
|
|
Join Date: Feb 2019
Location: Hot Springs, AR
Posts: 4,410
Real Name: Patrick
|
|
Senior Member
Join Date: Feb 2019
Location: Hot Springs, AR
Posts: 4,410
Real Name: Patrick
|
To the OP, did you verify the seal is riding on the center of the inner retainer on the side you were able to install?
__________________
2000 SR5 V6 Manual 4WD https://www.toyota-4runner.org/3rd-g...biography.html
2000 Limited V6 Auto E-Locker Sold 3/2022
|
|
Reply With Quote
|
12-25-2021, 12:41 AM
|
#14
|
|
Senior Member
|
|
Join Date: Aug 2018
Location: Ohio
Posts: 1,599
|
|
Senior Member
Join Date: Aug 2018
Location: Ohio
Posts: 1,599
|
Never had to work on splines, but that picture looks like a lot of mushrooming, not a slight amount.
|
|
Reply With Quote
|
12-25-2021, 01:16 AM
|
#15
|
|
Member
|
|
Join Date: Sep 2021
Location: Fayetteville AR
Posts: 776
|
|
Member
Join Date: Sep 2021
Location: Fayetteville AR
Posts: 776
|
Quote:
Originally Posted by thennen
Never had to work on splines, but that picture looks like a lot of mushrooming, not a slight amount.
|
Welder/fabricator for years. He can make it perfect with a little skill. Id put it on a lathe and spin it. Hit it with a tiger paw until you have the perfect diameter calipered on the outside grooves. The inner grooves going to be a little more difficult with the correct type of file. Do it for fun who cares if you **** up.
|
|
Reply With Quote
|
Posting Rules
|
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
HTML code is On
|
|
|
|