D30 broken axle shaft removal

[jscusmcvet]

I have searched and cannot find an applicable thread or write up.

My son broke his front axle shaft on his 2000 TJ during a serious stuck last weekend. He has standard gearing and an ARB up front. This morning I disassembeld the wheel, brakes, unit bearing assembly and removed the short stub. The ujoint was broken but still there. The long side of the shaft, inside the axle tube, is where the break occured. No ears left and the broken shaft about 1.5 inches inside the tube. I grasped the axle shaft with pliers and pulled, expecting it to come right out, but I cannot get it to budge.

My past expereince with front axle shafts is the Rubicon d44, which seems exactly the same, and the shaft has always slid right out. Is the difference the ARB?

Any suggestions on getting it out of the vehicle?

Thanks,

John

 

[Bigjerm]

Hmm I know my D30 shafts slid right out but the shafts on my 350 required some serious work. Been a bit since I looked at the carrier and never seen an ARB installed but if you pull the shaft on the other side and the bearing caps could you get out the carrier? I dont remember if there would be enough room.

 

[bob91yj]

Not sure if there ius a solid cross pin in an ARB or not. I'd pull the other side and see if the broken stub can be pushed through from the opposite side.

There is a chance that the shaft shattered at the splines and is wedged into the carrier which will require complete dis assembly.

 

[jeep-N-montero]

Not sure if there ius a solid cross pin in an ARB or not. I'd pull the other side and see if the broken stub can be pushed through from the opposite side.

There is a chance that the shaft shattered at the splines and is wedged into the carrier which will require complete dis assembly.

^This^

 

[Jim K in PA]

$5 on twisted/distorted splines. It will come out, but not without pulling the front cover and "persuading" it. Went through this on the trail last summer with a friend's XJ.

 

[jscusmcvet]

OK, so I pulled the passenger side axle assmebly and used a rod, past the cross pin and hammered against the end against the drivers side axle shaft.... no go...

So I welded a bar ont the axle shaft and pulled, hammered, etc.... and it is not coming out period. It will rotate independently of the diff if you spin the shaft and if you turn the diff by hand, the axle shaft turns.

My next step, I think, is to disassemble the diff, arb and all. That will most likely not be until next Sunday. I am open to suggestions if you got em...

Thanks so far.

John

 

[Stumpalump]

If the broken axel is stuck in the ARB the you won't be able to pull the ARB out. Pull the cross pin and beat it from one side and use a slide hammer on the other. In other words I think you may need to keep beating on it. Try tapping it in befor you hit it.

 

[jscusmcvet]

If the broken axel is stuck in the ARB the you won't be able to pull the ARB out. Pull the cross pin and beat it from one side and use a slide hammer on the other. In other words I think you may need to keep beating on it. Try tapping it in befor you hit it.

This is what crept into my mind last night when I was trying to sleep... not being able to remove the carrier becasue the shaft is stuck in there...

Thanks for the replies and I will keep you updated. If any more ideas, keep them coming...

Thanks,

John

 

[Stumpalump]

Before you spend any more time check to see if the axle tube has been bent. Look at where the tubes go into the pumpkin and look into the spot weld holes for any slight deflection. If its tweaked even slightly then pull it out first. I doubt/maybe it is bent bad enough to bind it but if you have to pull it out in the long run it may be easier to save the ARB with the axle out and on its end.

 

[jscusmcvet]

Before you spend any more time check to see if the axle tube has been bent. Look at where the tubes go into the pumpkin and look into the spot weld holes for any slight deflection. If its tweaked even slightly then pull it out first. I doubt/maybe it is bent bad enough to bind it but if you have to pull it out in the long run it may be easier to save the ARB with the axle out and on its end.

Thanks for this. I cannot see it being bent, but then again it was stuck on the bottom of a creek bed, where the sand washed away and the jeep sunk deeper and deeper... kind of like when you stand in the waves at the beach and sink deeper...

Point being as we did finally get it free it was the drivers side that was the last to come out and was angled (passenger side up first, then drivers side), so I guess that torque could have bent it a bit...

I also am going to try and take out the ARB cross shaft, so I can get a better angle on the shaft from the far side.

In any event, i will be working on it on Thursday morning, and will update then. Thank you so much for all your comments. I figure worst case scenario, I find him a used D30 and slap it in there and we cut that ARB out of the old axle... or something.

 

[jscusmcvet]

Dare I say...
V.I.C.T.O.R.Y....

Those of you who identified twisted axle splines were correct. I was about to give up and just pull the driveshaft and make it so he had a 2 wheel drive jeep for the time being. figured I'd give it a few more whacks for good measure.

It took full swing hits with a sledge hammer and then wiggling and pulling for it to finally loosen up. I had welded a rod onto the end of the shaft to pull with.

So far this morning I have cleaned everything out and have reassembled with new shaft. Letting the diff cover gasket set up and then will move on to the rear, just changing fluid in the diff and we should be good to go... well a few other minor issues, but those can wait.

Sure appreciate everyone's help.

John

 

[Jim K in PA]

Congrats John. These were stock shafts? Not that it necessarily matters. The D30 that I mentioned above broke last summer had Alloy USA shafts in it. The outer ujoint broke, and the inner splines were twisted. Not sure which happened first.

 

[BigAl]

Congrats, I as was reading your thread, I was thinking slide hammer since you said you had the ability to weld to the u joint.

 

[jscusmcvet]

Thanks guys. He is back on the road with all new fluids, etc... The clutch has a little chatter to it. With all the sand and mud and water, i imagine it could need to be replaced eventually.... Yes these were stock shafts and he runs 33x10.50's. good enough set up under normal circumstances. At it's worst, his front end was sunk in the sand until only the top 1/4 of the 33's were showing. Axle, everything under sand in running water... kind of like standing on the beach and letting the waves wash your feet deeper and deeper....

He got lucky and I still cannot believe we got it out. Took 6.5 hours, my Rubi and winch, his winch and a front end loader to get it out.

I am gonna put it all together in a post at some point. Just have to collect the pictures, etc.
John