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

[Bad Luck]

I would really recommend making sure that the seal is riding in the correct spot. If it’s not it will leak and that gear oil will wash out all the grease in the wheel bearing and you’ll most likely have to replace the wheel bearing once you fix the seal again

 

[mtbtim]

Well, I tried. OP, I don't care how cool those guys at the shop were, or maybe they even let you have your way with their sisters, the fact remains they screwed up your axle and then didn't even own up to it. In my opinion, that doesn't speak very highly of them. The guy who did the work had to have known he screwed up your axle yet he said nothing about. The guy and probably the shop itself lacks integrity. You let them get away with it and they've probably done the same to others and will continue to pass off shoddy work to their customers in the future.

But, it's your time and your wallet and it's clear you're ok with letting it go.

I agree with [MENTION=319302]Bad Luck[/MENTION]. Do yourself a favor and confirm you have a good mating of the inner retainer with the axle seal by performing a grease or sharpie test. Something tells me you're not going to be happy with what you find out.

 

[FiXXXerX]

Well, I tried. OP, I don't care how cool those guys at the shop were, or maybe they even let you have your way with their sisters, the fact remains they screwed up your axle and then didn't even own up to it. In my opinion, that doesn't speak very highly of them. The guy who did the work had to have known he screwed up your axle yet he said nothing about. The guy and probably the shop itself lacks integrity. You let them get away with it and they've probably done the same to others and will continue to pass off shoddy work to their customers in the future.

But, it's your time and your wallet and it's clear you're ok with letting it go.

I agree with [MENTION=319302]Bad Luck[/MENTION]. Do yourself a favor and confirm you have a good mating of the inner retainer with the axle seal by performing a grease or sharpie test. Something tells me you're not going to be happy with what you find out.

So, how psyched are you gonna be to learn that you were right? lmao out:

I got my used axle shaft in, it looks like it had actually had the bearing replaced here relatively recently, everything was good and moving the way it should and looked almost brand new. Aside from some damage to the dust shield in shipping, it was pretty much perfect after cleanup. And with brute strength and an artistic eye, I was able to bend the shield back to looking pretty damn good (Axle shaft was $35 shipped from eBay after the seller gave me $20 off for the damage).

HOWEVER, I noticed some things that looked different compared to the axle shafts done by the shop. So, I went and grabbed the one 'good' one, and set them side-by-side. Here are the results (OEM is on the left, and, clearly has the right tolerances):





- Bearing isn't seated properly in race
- Collar and toneloc ring have been pushed WAY to far down, way to far to seal.

So, checking was absolutely the right call it turns out. And in this case, I absolutely 100% went back to them and was like 'Look guys, I tried my best not to bother you with shit, but this is unacceptable'. Which they were receptive to and are going to fix the issue for me.

We'll see what that entails and if it's done properly, or if they get another tech to do it, who knows. But, I did want to let you know that your inclination was spot on.

I'll update you with what happens next!

 

[mtbtim]

So, how psyched are you gonna be to learn that you were right? lmao out:

I got my used axle shaft in, it looks like it had actually had the bearing replaced here relatively recently, everything was good and moving the way it should and looked almost brand new. Aside from some damage to the dust shield in shipping, it was pretty much perfect after cleanup. And with brute strength and an artistic eye, I was able to bend the shield back to looking pretty damn good (Axle shaft was $35 shipped from eBay after the seller gave me $20 off for the damage).

HOWEVER, I noticed some things that looked different compared to the axle shafts done by the shop. So, I went and grabbed the one 'good' one, and set them side-by-side. Here are the results (OEM is on the left, and, clearly has the right tolerances):





- Bearing isn't seated properly in race
- Collar and toneloc ring have been pushed WAY to far down, way to far to seal.

So, checking was absolutely the right call it turns out. And in this case, I absolutely 100% went back to them and was like 'Look guys, I tried my best not to bother you with shit, but this is unacceptable'. Which they were receptive to and are going to fix the issue for me.

We'll see what that entails and if it's done properly, or if they get another tech to do it, who knows. But, I did want to let you know that your inclination was spot on.

I'll update you with what happens next!

There's really nothing to be psyched about. I'm was just trying to give you good advice and not let that shop get away with screwing you over.

This rear axle seal/bearing job has to be the most commonly screwed up job dealerships, independent shops and machine shops do. You're definitely not alone.

I myself had this job botched for me by my local Toyota Dealer around 7 years ago. It was actually information I learned from this very forum to led me to find out they screwed it up. It was this botched job that got me off my ass to start doing most of my own wrenching. I quickly learned I could do just as well and often times better than the paid guys because I wasn't in a rush to get to the next job. I take my time and get it done right.

I always tell people with the Right Information, Right Tools and Right Level of Patience, people can be very successful doing their own wrenching. Maybe this experience will motivate you to buy a press and invest in more tools. A harbor freight press and the special service tool would have saved you a lot of headaches. Something to think about. Tools are an investment that quickly pay for themselves and continue to save you money over time. My advice, make the investment.

 

[Sarki]

I absolutely 100% went back to them and was like 'Look guys, I tried my best not to bother you with shit, but this is unacceptable'. Which they were receptive to and are going to fix the issue for me.

We'll see what that entails and if it's done properly, or if they get another tech to do it, who knows. But, I did want to let you know that your inclination was spot on.

I'll update you with what happens next!

Hate to say it but I wouldn’t be giving these guys a second chance as based on the pictures I see 2 possible scenarios:
1) They knew they screwed it up and sent it on it’s way or…..
2) They have no idea what they’re doing regarding the installation/positioning of retainer based on the revised seal.
Sometimes best to cut your losses and find someone that has first hand experience doing this particular job or like Tim suggested, buy the HF press and related tools and get it done 100% correct.
I did the above as I didn’t have faith in shops in my area and figured I would invest in a press and a few new tools and take my time doing the job.
Glad I did as now I have a sweet 20 ton press which I’m using to replace my suspension bushings, etc.
Got my fingers crossed the shop corrects the problem and your rear axles remain leak free.

 

[Bad Luck]

So, how psyched are you gonna be to learn that you were right? lmao out:

I got my used axle shaft in, it looks like it had actually had the bearing replaced here relatively recently, everything was good and moving the way it should and looked almost brand new. Aside from some damage to the dust shield in shipping, it was pretty much perfect after cleanup. And with brute strength and an artistic eye, I was able to bend the shield back to looking pretty damn good (Axle shaft was $35 shipped from eBay after the seller gave me $20 off for the damage).

HOWEVER, I noticed some things that looked different compared to the axle shafts done by the shop. So, I went and grabbed the one 'good' one, and set them side-by-side. Here are the results (OEM is on the left, and, clearly has the right tolerances):





- Bearing isn't seated properly in race
- Collar and toneloc ring have been pushed WAY to far down, way to far to seal.

So, checking was absolutely the right call it turns out. And in this case, I absolutely 100% went back to them and was like 'Look guys, I tried my best not to bother you with shit, but this is unacceptable'. Which they were receptive to and are going to fix the issue for me.

We'll see what that entails and if it's done properly, or if they get another tech to do it, who knows. But, I did want to let you know that your inclination was spot on.

I'll update you with what happens next!

The inner retainer (closest to the axle splines/furthest from the wheel studs) needs to be flipped around for better sealing with the new design inner axle seal. I hope they get it right the second time around, but I wouldn't get my hopes up.

 

[FiXXXerX]

There's really nothing to be psyched about. I'm was just trying to give you good advice and not let that shop get away with screwing you over.

This rear axle seal/bearing job has to be the most commonly screwed up job dealerships, independent shops and machine shops do. You're definitely not alone.

I myself had this job botched for me by my local Toyota Dealer around 7 years ago. It was actually information I learned from this very forum to led me to find out they screwed it up. It was this botched job that got me off my ass to start doing most of my own wrenching. I quickly learned I could do just as well and often times better than the paid guys because I wasn't in a rush to get to the next job. I take my time and get it done right.

I always tell people with the Right Information, Right Tools and Right Level of Patience, people can be very successful doing their own wrenching. Maybe this experience will motivate you to buy a press and invest in more tools. A harbor freight press and the special service tool would have saved you a lot of headaches. Something to think about. Tools are an investment that quickly pay for themselves and continue to save you money over time. My advice, make the investment.

I apologize for making it seem like I thought you would enjoy the fact that this happened, that's not what I meant at all. I know you're a hell of a dude that wants to help fix everything, so, I apologize if that's how it came off!

Got the axle shaft back from the shop today and it's all perfect and in spec. Did a grease test just to make sure, and it was good to go.

As far as the tool situation goes, I've got just about everything one could need, with the exception of a few tools. All of the work I do I do in my driveway open to the elements. I don't have a garage, and while I did recently build a shed, it's not entirely usable as it's so full it might burst. So, unfortunately there isn't anywhere for me to fit a press right now. I ALMOST bought one and the special tool used to installation and removal, but my wife would murder me if I put it on the porch (I've already had to let her use my drag-slick wheels as plant holders 'cause I can't put them anywhere else, lol).

So hopefully in the future here, I build a robust shed, or I build some sort of car port/enclousure/garage. But time will tell!

Thanks again for your help, I don't know if I would have caught it without having my eyes looking for mistakes to begin with.

 

[FiXXXerX]

The inner retainer (closest to the axle splines/furthest from the wheel studs) needs to be flipped around for better sealing with the new design inner axle seal. I hope they get it right the second time around, but I wouldn't get my hopes up.

I know the MrCoffee mod is a thing, but it's hard to tell a shop that's already had issues installing something to OEM specs, to install something def. not in OEM.

That being said, while I absolutely get the fear with the new design, I did a grease test and it's sitting middle of the way in on the retainer, which should be more than enough to keep it sealed.

Next time hopefully I'll have a press and a garage

 

[Sarki]

I know the MrCoffee mod is a thing, but it's hard to tell a shop that's already had issues installing something to OEM specs, to install something def. not in OEM.

That being said, while I absolutely get the fear with the new design, I did a grease test and it's sitting middle of the way in on the retainer, which should be more than enough to keep it sealed.

Next time hopefully I'll have a press and a garage

Glad to hear it worked out.
Keep an eye on it to make sure no leaks each time you do an oil change.