To read the original full thread and post questions/comments on this topic, please go to Lessons about CV axle failure
For a detailed replacement and repair procedure for the CV axle, please go to this Technical Article:
CV AXLE: Replacement and repair w/ pics
This post simply to provide useful information for everyone- it is
not an indictment of the owner or bragging on my behalf.
This weekend I was at Katemcy Rocks at the Lone Star Land Cruisers annual Roundup. I had just completed a rocky hill climb and was watching the rest of the group negotiate the hill when I saw an FJ Cruiser about halfway up struggling. He was trying to transition from a low ledge he was on to a higher ledge on his right, with his wheels turned hard right and his foot on the gas. I knew immediately what the likely result would be, so I chuckled and watched (and grabbed my tools). Sure enough, he mashed the gas and started bouncing... after about 3 bounces I heard the *BANG* and I proceeded down the hill.'
Lesson #1: If you are turning your wheels sharply and/or climbing an obstacle, picking a better line is often a wiser choice than pressing a bad position.
Lesson #2: If you are spinning your wheels and it starts to hop, get out of the gas and stop immediately. The second a tire spinning at 10-15 MPH gets traction, something bad usually happens.
I got down to the vehicle and discovered that the driver had no tools, no axle, nothing.
Lesson #3: Be prepared when you head out, and do not count on or expect others to take care of you. Know how to perform basic trail repairs and have the parts and special tools (in this case: CV axle, 35mm hub socket, gear oil, right & left diff seals and a means to pull & seat the seals, locktite and FIPG) to repair your own stuff.
Even if you don't know how to perform basic repairs, at least have the parts and tools so that someone can help you and someone else who made the investment for themselves doesn't end up without spares because of your lack of preparation.
So, the other FJC in our group (Graham) had a spare axle. I sat down and pulled the axle out. I discovered that the axle shaft had broken just inside the differential.
Now I was posed with an interesting challenge- I could pull the other axle out and drop & separate the diff to recover the inner axle portion that was held in place with the C clip and swap in a new axle (I had FIPG & gear oil and everything with me), or I could put together a trail fix for him. Since he had (for some unknown reason) trailered his FJC to the event, we opted for a trail fix.
I proceeded to attempt disassembly of the outer joint (it is a Birfield), but could not get it apart. Before resorting to using a hacksaw on the axle, one of the trail guides called in a Jeep that had a power inverter and a grinder with a cut-off wheel and we cut the cage to release the balls and separate the outer stub.
Lesson #4: If you have a stupid "anti-whatever" sticker (Jeeps, Hummers, whatever), take it off. If you have a stupid "anti-whatever" attitude (Jeeps, Hummers, whatever), grow up and lose it.
Lesson #5: If things take a serious turn for the worse, inventory all possible resources at your disposal and communicate with everyone where you are at and what you need.
One of the FJC Trail team members was getting frustrated at the time it was taking and told me to simply put it back together. He even called a "technician" somewhere who told him to try and run it with nothing supporting the bearing. I explained to the driver why I was doing what I was doing and left it up to him- he opted to permit me to continue. After the cage was cut and the outer stub was put back in and everything was ready to wheel him off the trail, a Toyota master technician called back the FJC Trail Team member and told him the repair I performed was exactly correct.
Lesson #6: The driver has the ultimate responsibility for approving the repairs done on his vehicle. The driver should also understand that if he wants the vehicle fixed he needs to let people who know how do it, and likewise understand that they are helping him at their inconvenience. This means that you ask questions and be informed, but do not be bossy. Also, do not let others pressure you into making decisions you feel may not be the best.
Lessons #7 & #8: Do not let impatience cause you to search for an answer that you want to hear, and if you know what is the right thing (not the easiest), then do it.
I could have easily just stuck it all together and said "What the hell- it's not mine, he wasn't prepared, it's f***d anyways, whatever", but that wouldn't have been right. He was a nice guy, and he will be a better wheeler because of the experience he went through.
So please, before you blast out to wheel your vehicle, please take the time to read and understand all you can; not only about the correct techniques of off-road driving, but the likely failures and what you need to do to prepare for them. You do not have to have a Snap-On box full of tools and parts, but simply a basic understanding of how to make a vehicle safely drive off the trail and back to camp and the capacity to perform those repairs.
Lesson #9: Beer or food is an acceptable (and expected) expression of gratitude... don't be a bogart.
Final Lesson: Don't judge someone by their "forum persona".
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