Dana 44 axle break (guru input)

jeudi 20 août 2015

Bit of a story. For the TL;DRs, look at pics and enjoy the carnage!

Loaded up the Jeep for a trip from Kansas City, MO to Kalispel, MT last week and headed out after I got off work. We're about 400 miles in, things were going ok until just after we refueled in Sioux City, IA. We hop back on the interstate and cross into South Dakota, and we hear a strange noise that sounded like a rumble strip and start seeing flashes of light behind us. Rear left wheel was on fire.

A douse of water later and we decided to limp the thing down the shoulder to the next exit a quarter mile up. We didn't make it. Rear end suddenly started off tracking and we pulled completely off the road and called AAA. (Pic is after my brother towed the poor thing home)




Cut to when we get back home and tore the wheel off. Clearly we knew the axle was broken, but what was strange is it wasn't from a bearing failure from what we can tell. Yes the bearing died but the break happened underneath the retainer ring, not because the bearing locked up (and wheel bearings were replaced only a few thousand miles ago because the old seals went). In fact the outer race barely was touched as you may be able to see.







So I guess other than posting the pics of the carnage for everyone to enjoy, I'd like to hear some takes on why this happened and if I should be worried about it happening to the other side when I replace the axle, bracket, seals ect. (Yes, it will be well cleaned up and flushed before I run it again. )

My only theory has to do with whoever removed the bearings from this shaft before we bought it. It appears someone may have taken an air chisel to the bearings instead of cutting them off with a cutoff wheel. Judging by the marks and cracked bearing race we found, it may very well have put stress cracks in the shaft. See for yourself:



Very thankful the caliper bracket held the wheel on, we were very lucky.


Dana 44 axle break (guru input)

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