jimdoss

The break was about half way around, starting at the bottom. Other than some local desert exploring this winter, my next big trip isn't until my annual Death Valley trip in March. I hope to have something figured out by then.

karls10jk

I'm looking at this now, though I usually don't, and I'm noticing what looks like a plug weld towards the left of your picture. Was that done before or after the break? Any other plugs anywhere to keep the inner and outer sleeves together?

jimdoss

The sleeve was also welded at the ends. See photo. The plug weld was from the sleeve install, years ago.


Driver's side sleeve weld.

bkg

is there a plug weld between the repair and the diff housing?

If not, torsional stress explains the break... If the sleeve isn't welded all the way into (for lack of better term) the diff housing, there isn't really anything strengthening the housing torsionally.

karls10jk

I guess that explains why the manufacturers on those kits look for plug welds all down the length of the sleeve and on each side. It basically makes the two into one instead of an axle tube with a sleeve. The sleeve probably saved you from catastrophic failure when the crack started but wasn't quite enough to save the tube from the crack.

resharp001

That is what I was thinking. You always hear how sleeves really don't do a whole lot to strengthen the axle, but I do think in this case that is what kept things together and got him off the trail. What a downer. Hopefully that didn't put any damper on the overall trip!