The axle in my truck tried to escape. While driving at 70mph!

[LovesDunes]

I forgot to tell you guys about my exciting day last week.  I was on my way to Spring Valley to actually visit Bob at Bengels and Ed at PSD.  While traveling on the 94 east this guy pulls up next to me honking.  I waved thinking maybe I had cut him off.  Sorry dude.  Then the car behind him pulled up and was honking also.  I thought it was wierd that I could have pissed two guys off in such a short amount of time.  I started to look around to see if I could see anything odd.  I did not see anything but just as I was about to settle back into my seat and continue driving I noticed an odd site in the drivers side rear view mirror.  The end of my axle was sticking out about 16 inches.  ~eek  I pulled over to the side of the road and the first thing I thought of was that I need a picture of this.



I figured since I was heading to Spring Valley anyways I might as well keep going.  So I tossed the axle into the back of the truck and drove on.  Of course making a mess with what little oil I had left in the axle housing.  Bob had already left for the day so I went across the street to see Ed at PSD.

The wheel, tire and side of my truck was quite a mess.  The smell was the worst part.










A few broken bits and two bolts removed I was able to get home so I could fix the problem...




I removed the two bolts and pulled the axle and noticed the holes in the hub don't look so good.  It appears that the bolts had been loose for a while.  Yikes...






With my trusty sharp bit and easy out I was able to easily remove the rest of the broken bolts...






What was left of the bolts.  The missing bolt heads I guess were flung off on the highway.  I hope they didn't hit anything.  The bolt heads that were left were held in place on the axle by the RTV.




After removing the bolts and cleaning everything up...




I installed the new bolts Ed gave me and we were good to go...





If the axle had made it all the way out of the housing on the freeway I'm sure this story would have had a much different ending.  It's pretty scary to imagine an axle tumbling down the freeway.  I'm glad I hate centercaps.  It would have been awhile before I even knew anything was wrong.  With the locker in the rear the truck drove just fine with one axle.  I have since replaced the grade 8 bolts with grade 9 and check the torque on the bolts often.  I'm going to replace the bolts with studs eventually.

[Metal Twister]

Holy Smokes Pete!  That could of been very ugly! Im always there late, im wondering what night it was? Anyway Im glad it turned out ok and its already back together. Im thinking maybe stainless safety wire or those fold over washer tabs might be in order?

 ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops ~oops 

[DavidWymore]

Studs and nuts, fo sho.

[LovesDunes]

It could have been really disasterous for sure.  Some sort of mechanical device would help to keep the bolts tight for sure.  But the biggest problem is that Dana used fully threaded bolts.  The holes in the axle for the bolts are slightly too big so if the bolts come loose the axle is allowed to slop back and forth.  With a locker in the rear, every time I go around a corner the axle just slams against the bolts.  With studs there will be the small section that's not threaded and that fits into the axle hole really nicely.  So on the off chance the nuts or studs come loose at least the axle won't be able to wiggle very much.  Nylock nuts should stay nice and tight.

[DavidWymore]

Be careful. Nylocs are often only grade 2. Grade 5 or 8 Stover or crimped nuts are better.

[LovesDunes]

Good call thanks. 

[SNOTROCKET]

i know this is an old thread but i just noticed the subject and had to read it.

DAMN!!! i think im going to go check mnine right now. and i like your idea about not keeping the center caps. i have a felling that those are not going to make it back on the ford.

[LovesDunes]

The studs and nuts have worked great with no problems...