Axle restoration

Part 1

I removed my OEM axles about 10 years ago and fitted cheap Chinese ones, less than 10k miles later and there is backlash in the Chinese ones so I decided to rebuild my old original OEM ones. I decided to remove them due to the cracks in the boots although they had not completely failed.

 

First a clean in detergent.

 

Then de-rusted with a poly disc on the angle grinder.

 

Next, removing the boot at the smaller end, I think using oil rather than grease helped with their longevity.

 

 

 

Part 2

The next step was to remove the "can", I used an angle grinder.

 

The can can then be slipped off.

 

The joint will easily fall apart.

 

I carefully measured the position of the axle part (for reassembly).

 

Then pressed it off.

 
 

Part 3

The ends of the early axles are different sizes, there is a larger "can" on the inner end which is not replaced and needs a larger boot which is NLA. I only found one of the correct boots.

This is the part number for the larger boot.

 

Here is a comparison of the two boots together.

 

Most shops sell only one size for both ends. I had to stretch a smaller one over the large end for one of the axles. The supplied clip was too small.

 

I used better quality clips from HCL.

 

 

Part 4

I used this gear oil in the joints, the exact quantity is given in the workshop manual.

 

Next I reassembled the outer joint. Once the boot and "can" were on the shaft, I hammered the spider gear back into its original position ready for crimping.

 

Now this is the difficult part, I ordered these five pieces of steel from a laser cutting company.

 

Next I tac welded them together before drilling.

 

Drilled in the corners so they could be bolted together.

 
 

Part 5

Next the ring was welded to the base to position for more drilling.

 

The next part was to create the crimp profile, I shaped a piece of HSS to match the crimp on the old axles.

 

Then I used the lathe to creat both parts of the crimp.

 

 

Ready for a trial crimp.

 

Part 6

Ready to assemble.

 

Axle in place.

 

Clamping ring in place.

 

Tightened down.

 

Crimp complete.