Axle Tube Crack

The left side of the mark goes down to zero as a crack would. A cutting disk wouldn't leave a mark like that. Plus, it was stated that a scope was used? nwedgar, did it look the same on the inside of the tube?

I'm dying to know what caused it.

 

My first thought also was a cutting disc scar from cutting off old u bolts but after staring and scratching my head and staring some more I do not believe it is. It would be a strange place to cut a u bolt as it would require 2 cuts as apposed to the 1 most of us would do at the top of the axle. I think if that were a rat patrol scar there would be a lot of other damage elsewhere such as a cracked center section and a bent frame. I am baffled. That said I think there is nothing to lose by trying to weld it.

 

So, I'm thinking the axle may have been salvaged from a Jeep that was in a high impact crash...

 

Over tightening the u-bolts or allowing them to run loose with aggressive driving can cause the same issue. Take a close look at the tube where the u-bolts wrap around the tube and if it shows signs of no longer round then that is a likely cause. Seen it many, many times.

 

nwedgar, I am in Atlanta. Can you suggest a good machine shop that knows cjs in the metro area?

 

James, sorry I don't know of any shops that know CJ's. I've done all of my own work with the exception of engine machining. Having said that there are a few good 4x4 shops that may have some expertise depending on what you need. Try Classic City Off Road...on the NE side of town.

 

Nailed it Nick. Finally had a chance to un-mount the axle and it's pretty clear that the ubolts were too tight based on the groove in the tubing and the fact that it seemed to draw the spring mount into the tube so the tube is no longer round. The cracks on both sides of the axle (driver and passenger) are at the front where the spring mount is welded to the tube. Probably due to me over torquing the bolts on an already weak tube. I'm not an aggressive driver, but I imagine that a 360 in front of a T18 will result in some axle housing rotation which probably contributed.

I'm still going to weld the crack as best I can so I can use the Jeep until I can find a good replacement axle housing. I think I'll be okay unless someone on here tells me that it could result in a catastrophic failure causing my death and maybe others.

 

Thanx Norm.

 

A mask with filters does not protect you from Phosgene Gas, it requires an actual hazmat suit! Here is a couple links to the CDC talking about exposure. Your not suppose to even take a shirt off over your head after exposure, and all clothes need to be double bagged and treated as hazardous waste!

Never use brake cleaner on ANYTHING you are going to weld. Carb cleaner is fine as it does not produce Phosgene gas when burnt. Since it is meant to be burnt going though the motor.

CDC | Facts About Phosgene
CDC - The Emergency Response Safety and Health Database: Lung Damaging Agent: PHOSGENE (CG) - NIOSH