Slightly mushroomed Axle shaft splines... how to fix?

[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

 

[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.

 

[FiXXXerX]

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

 

[jlaho]

Good deal! Give us all an update on how it goes? Oddball issues like these are neat to follow.

 

[spartacus]

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.

 

[bmason8159]

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

 

[mtbtim]

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.

 

[Jakeepoo3]

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.

 

[Romeo1]

That axle is toast. Looks like they didn’t know what they were doing.

 

[sportscarfan]

File to fit. It'll be fine.

 

[Sparky 97Runner]

They must have used this video as a tutorial. Fast forward to 5:30.
Install Toyota Rear Axle Bearing, Oil Seal - WITHOUT a Press! - YouTube

 

[T4R2014]

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?

 

[Bad Luck]

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?

 

[thennen]

Never had to work on splines, but that picture looks like a lot of mushrooming, not a slight amount.

 

[Jakeepoo3]

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.

 

[mtbtim]

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.

Yeah, but who has a lathe in their garage? Not many. He'd have to bring it to a shop for that.

 

[thennen]

Well, I’m thinking garage mechanic and hand tools. No lathe or tiger paw in my world lol. Regardless, it looks like it was hammered a good bit. Brass hammer/punch may have been less harmful?

 

[Jakeepoo3]

Well, I’m thinking garage mechanic and hand tools. No lathe or tiger paw in my world lol. Regardless, it looks like it was hammered a good bit. Brass hammer/punch may have been less harmful?

Files will do the trick. You'll need a good precise one for the inner grooves. I forget the name of the file. It's a three sided triangle shape with a fine point to get the grooves completely right so you don't damage the mating splines. Putting back in.

 

[FiXXXerX]

Sorry for the delayed response to everyone here, but, Holidays....

So, I worked on it, tried my damndest to get it right. Busted out the digital calipers, had some nice files, etc. But even when I was able to get it to work a little it still wouldn't finish going in.

I ended up working on it for longer than intended, forgot to eat and busted out a BFH. This did not help, but it did give me witness marks to follow!

Before I broke anything, the wife arrived home and insisted I put the 5lb Sledge down and eat something. (I did test the other axle shaft to make sure I didn't mess anything up and everything goes together perfectly and turns and sounds beautiful)

I did that, found reluctance to keep working on it and found a used one on eBay for $55 shipped that should be here today.

To answer the question as to what I paid and why I'm reluctant to go back to the shop complaining, I paid $100 to get both axles rebuilt, paid cash and provided parts, the shop let me pay the tech directly and he worked on them when he was in between jobs for the shop itself. They were super cool about doing the job, and, were $200 cheaper than the next place that offered. Do I wish it went better? Sure. Did I get one side done? Yeah. Should I check that side with grease for witness marks... probably. But I don't really know what going back will help with at this point, and I'm not really sure what I'd 'Want' from them (New bearing and other parts? I'm not sure I'd want guys working on another axle shaft after they were officially upside down on the job), plus, shit happens.

So, I'm going to wait for the new shaft to get in, see what the condition of everything is, and if the bearing looks good... it's going in without a rebuild. The only reason these guys got fragged to begin with was because of the breather valve it appears, and I've got a whole relocation kit for that now, so it shouldn't happen again. If I've got to rebuild the 'new' used axle shaft months down the line here, so be it. If it needs a rebuild now, fine. But I'm tired of not being able to drive my truck and my GTI looks like it has a starved bearing in one of the balance shafts, so, I've gotta go light that whole thing on fire now. :sobbing:

I really appreciate everyone's input here! And I'm not sure that I'm done messing with the other axle shaft just yet... but, who knows!

 

[thennen]

Sorry for the delayed response to everyone here, but, Holidays....

So, I worked on it, tried my damndest to get it right. Busted out the digital calipers, had some nice files, etc. But even when I was able to get it to work a little it still wouldn't finish going in.

I ended up working on it for longer than intended, forgot to eat and busted out a BFH. This did not help, but it did give me witness marks to follow!

Before I broke anything, the wife arrived home and insisted I put the 5lb Sledge down and eat something. (I did test the other axle shaft to make sure I didn't mess anything up and everything goes together perfectly and turns and sounds beautiful)

I did that, found reluctance to keep working on it and found a used one on eBay for $55 shipped that should be here today.

To answer the question as to what I paid and why I'm reluctant to go back to the shop complaining, I paid $100 to get both axles rebuilt, paid cash and provided parts, the shop let me pay the tech directly and he worked on them when he was in between jobs for the shop itself. They were super cool about doing the job, and, were $200 cheaper than the next place that offered. Do I wish it went better? Sure. Did I get one side done? Yeah. Should I check that side with grease for witness marks... probably. But I don't really know what going back will help with at this point, and I'm not really sure what I'd 'Want' from them (New bearing and other parts? I'm not sure I'd want guys working on another axle shaft after they were officially upside down on the job), plus, shit happens.

So, I'm going to wait for the new shaft to get in, see what the condition of everything is, and if the bearing looks good... it's going in without a rebuild. The only reason these guys got fragged to begin with was because of the breather valve it appears, and I've got a whole relocation kit for that now, so it shouldn't happen again. If I've got to rebuild the 'new' used axle shaft months down the line here, so be it. If it needs a rebuild now, fine. But I'm tired of not being able to drive my truck and my GTI looks like it has a starved bearing in one of the balance shafts, so, I've gotta go light that whole thing on fire now. :sobbing:

I really appreciate everyone's input here! And I'm not sure that I'm done messing with the other axle shaft just yet... but, who knows!

You're probably taking the best approach. You have to know when to tap out and reduce the stress level, which it sounds like you're doing. It'll all work out fine anyway, I imagine. And it rarely pays to beat the heck out of a shop that seems to have tried to work with you. Even if it's a bad shop, be civil and simply don't go back is my standard approach.

Best wishes!