2-Big Broncos 4x4 Technical White Papers
Members and associates of the 2-Big Broncos 4x4 club have written the
materials contained on these pages. Authors offer no guaranties
on the usefulness or accuracy of the writings. Authors and the
2-Big Broncos 4x4 Club are not responsible for any information or
actions taken by you for using this information.
Take this information for "face value" and use with your own discretion and wisdom.
Broken front axle removal - 1990 Model year
You broke it, now you can fix it!
UPDATE: I have completed all of the repair that I am physically and mentally able to! I got the
wheels back on, sans right axle shaft... in preperation for a profesional to get at it! I plan
on putting in a PowerTrax LockRight in the rear and later this year, another
one in the front.
For the curious at heart, here is a pic of what broke up front.
The partial shaft mates to another partial shaft (not pictured), which was
ALREADY BROKEN during the fatal tug-o-war. Also, about
half the gear damage shown in this picture was already there!!!
I would of opened a really big can of whooop a** on that K5 Blazer
had my front and rear ends actually been OK!
The "Damned" Chevy
The Haynes Truck manual was my guidebook. These books in my opinion far exceed what you need
to take apart, and put back together almost any common assembly on your truck. But
first let's set something straight -- about the fateful tug-o-war -- -- I won.
Before that happened, here's a shot of the muddy horse (most graphics
are expandable, just click them and use the back arrow to return here).
Click thepicture, son!
After it happened, things looked like the following...
of all the parts that broke on the front)
The rest of this page shows my attempts at repairing and documenting
the repair. Most pictures are clickable.
The result was a broken U-joint carrier on my Slip Yoke. The slip yoke
is the connector between the spline stub shaft (which juts outta the diff),
and the axel shaft proper. With that piece broken, you pretty much
have to take every wheel component off so you can yank out the axel.
First you have to remove the Tire and Rim (duh), that exposes the disc
and hub as shown.
The hub has five torx head bolts holding it down and a little spring
in the middle. Once removed you expose the hub and the hub cover spring
and bearing. The spring is in the hub cover, and the bearing should still
be stuck on the hub as shown next.
Remove the bearing and look for the lock-ring retainer.
Removing this will allow you to compress the retainer ring and remove
the auto-hub itself.
Once the hub mechanism is out, you need to remove a splined spacer shown
here. Followed by a 'C' washer in a groove. Look around, it's there. Next
is a holy greassssy lock washer (a lock washer, grease covered, with holes
in it Batman), behind
that is the bearing retainer nut.
Before you take the spanner nut off, you'll have to remove the Brake
On mine it was held in place by some slide pins. Get the Haynes book,
it tells you all about it.
Removing the bearing lock nut, or spanner lock nut, requires a special
Spanner Locknut Wrench ($12.99 most places). You'll need that later putting
it back together. Oh, make sure you have a torque wrench that fits this,
it should be a 1/2 inch with at least 140 ft lbs on the dial. The book
says to tighten the final retainer nut to 150 ft lbs... ouch!
Once you have removed the spanner locknut, the bearing will come out,
and the hub is set free. The next picture is to show the placement of the
locknut and bearing in relation to the spindle. It's a mostly useless picture
because the bearing race, the inner bearing race on the hub isn't there,
you have to use your imagination!
Once the hub is off, you can release the six nuts holding the spindle onto
the camber plate (is that what it's called?). Once that is done, you can
yank out the axel.
You're done. The other side is the same, roughly, just a little more messy
when the axel comes out. You'll lose diff oil if you pull it, and watch
out for the seal. If you bust it, it's take apart the diff time!
Here's a little picture showing the final results, with most parts on
a cloth. God help me put'em back together!
Mark Christy -- firstname.lastname@example.org
1990 Bronco XLT
Reminder... Contact 2-Big Broncos