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Damaged Axle during bearing replacement

I’ve seen where guys have torched the bearings off of axle shafts, steady bearings, posi units etc and never seemed to have a problem. Kim
 
What is the most likely place for an axle to fail? Splines, lug studs, middle of the axle? Nothing i have would ever make that much power so just curious.
 
I've never seen or broke an 8 3/4 axle shaft. Run plenty in the low 11s with slicks for years. Plenty in the 10s as well. The only ones that ever showed any twist in the splines were from a 4 speed car with slicks.
Doug
 
I had a narrowed 8 3/4 under a V8 Vega. Shortened resplined axles. They weren't rehardened properly. Twisted the splines with G60-14 street tires...... but they never broke.
The 55-57 chevy 10 bolts I (and many others) broke, always broke where they necked down right after the splines.
I think those rears were plastic.
 
Sam69sat said:
What is the most likely place for an axle to fail? Splines, lug studs, middle of the axle? Nothing i have would ever make that much power so just curious.
Click to expand...
Where ever there is a damaged spot on the shaft. Like this cut. 8.75 and Dana axles don't seem yo break, but splines will twist.

oldkimmer said:
I’ve seen where guys have torched the bearings off of axle shafts, steady bearings, posi units etc and never seemed to have a problem. Kim
Click to expand...
Yes they can be torched off, the heat is in the bearing and the axle shaft not hot enough for any damage. Lots of old timers at the shops used the torch on many things, like melt a broken bolt out of a hole, and not touch the threads.
 
Last edited:
You might sell the car someday.
And how would you feel if the guy selling it to you said. "I cut the axle by accident when I was replacing he bearings, but don't worry. Most of the guys on the website said it is no problem."
Cheap insurance and the right thing to do. You can buy new axles from many sources.
 
The axle is going to break [ if it in fact does break ] where it is thinnest/weakest, which is usually where the splines end. Where the damage on THIS axle is in the thickest part of the axle, & that area is re-inforced in operation by the inner brg race. Axles usually break from one too many twisting motions, & there are weaker areas on the axle to twist other than where this grind mark is.
 
Show me a broken axle where it was nicked on a bearing change. You can't. To many keyboarders who never repaired cars.
Doug
 
I still think my answer in #15 is the right one
If it bothers you.... find another and decide if you wanna pay what it costs.
For a complete stock driver.....It wouldn't bother me, I'd run it. If it breaks (I sure don't think it will!) then find a new one.
For a race car..... I might consider replacement.
 
AS mentioned, it's up to you and your piece of mind, but, that section of the axle shaft is not where they break under extreme conditions. I'd run it not give it a second thought.
 
All those clutching their pearls over it breaking or twisting obviously have never changed out those axle bearings themselves or been in this hobby very long. I am going to say that MANY axles in everyone's cars right now have similar nicks and cuts but you don't know it because you paid someone else to do it.

As stated, smooth out any sharp edges, install the bearing and run it, that axle is going to out live you most likely.
 
Run it, with the pressed on bearing you will have ample warning before it parts ways.
Do you really think a 1/16 of an inch is the weee bit extra to keep it from catastrophic failure?
If it was a impact dent the surface i might be concerned, wearing away a little bit of metal with a grinder, not really.
 
Do you know how many of these are running around with Nick's in them? Every time I replace one I see a Nick underneath it. It's okay run it
 
That nick will do next to nothing to the strength of the axle which is by design incredibly strong. The only issue is the sharp edges of the nick that could act as stress risers for fatigue failure at some point in the future. I'd file down the sharp ridges and run it without a second thought.
 
Thanks all! I ended up finding a pair of axles off ebay that are correct for my Dana and reasonably priced. (Side note: found out I have 23 spline axles) I'll keep the nicked one around as a spare in case since most of the aftermarket are 30-35 spline setups.
 
Run it until you decide to put the 14/32's on! not gonna break until you start trying to twist it regularly.
Be careful next time! Now you've learned something!
 
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