I blew a cap on my d-side axle u-joint today. I pulled the inner shaft and plugged the axle tube until I can either get a new u-joint or axle shaft assembly.

I notice that the inner shaft had a noticeable groove one one side of the shaft at the location where it sits inside the inner axle seal. It's an 07 JK with 52K miles on it. I replaced the D30 u-joints about 20k miles ago and didn't notice any marks at all on the d-side axle shaft--though the passenger side did have a very slight groove where it sits in the axle seal. I lost the cap less than 9 miles from my house (lucky me). The ears appear to be okay, but I'm probably just going to order a new axle shaft assembly from Q-tec.

My concern is that I'm going ruin a new axle shaft if the inner seal is messed up. So my question...do I need new inner axle seals? If not, what would have caused the groove in the axle shaft? ...and is the groove normal wear...is it going to be a problem?

 

Seals will normally mark the shaft, without damaging it. How much of a groove is there on yours?

Can you post a pic of the groove?

It is very possible removing and replacing an axle shaft will cause you to need a new seal.
Unfortunately, the front axle seals require removal of the differential.
I would think it's worth trying to get by without replacing the seal.

 

Thanks for the quick reply. I'll post up a pic tomorrow after I get home from work.

 

After some sleep and some thought, I think the groove was caused by the plastic axle guide. It's supposed to sit back against the left ridge on the axle shaft, but it's possible that I pulled the shaft back slightly after sliding it into the tube. The shinyness to the right is where the axle seal should be making contact...that wear seems normal.






In the last zoomed pic, it almost looks like melted plastic on the shaft. I've already ordered a new d-side axle shaft assembly, so this shaft is going to be a trail spare. So, if that's what caused this...word of caution then when reinstalling shafts. That little plastic guide ring can damage your shaft if it's not seated correctly :( They're not needed, but they do make it easier to get the shaft through the inner seal.

 

Good pics!
I have been curious about the axle guide. Is it a loose fit on the axle?
When inserting the axle, would the guide tend to slide on the axle, making it useless?

 

The guide should be pushed in by the rusty ridge to the left of the shiny spot on the shaft picture. It's supposed to spin relatively freely in the axle tube. I must have pulled my shaft back out a bit after sliding it in, causing it to shift out of position. Making sure the axle tube is as clean as possible before sliding the shaft in is probably a good idea.

 

Thanks for the info.

 

I know this is old Ron, but I have my D30 apart and thought I would snap this picture of the plastic guides.

 

Thanks. Will the guide slide to the left on the axle in the picture? I wonder how it stays in place as the axle is slid into the housing.

 

There is a ridge on the axle and that is as far to the right they will go. You can see the small ridge on the first pictures at the beginning of the post.

ALSO......mine have two plastic guides on each side pushed together. I almost didn't notice I still had one in one side of my axle.