Has anyone had/heard of badly worn axle spines shearing off?

yep, the different drive flanges swap straight over, if your replacing either the flange or the axle due to spline wear you replace both...

i strongly suggest looking at the maxi drive items from MR auto.

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Originally Posted by Dougal

A year or so ago there was a picture of just that. On the front no less.:(

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Sometimes a man's gotta do what a man's gotta do Marylou.It might have been an emergency 'lets get out of here and get home' patch up job, where 4wd was a necessity, that can be sorted later with an angle grinder.
The set of badly worn rear shafts and flanges I welded up for a mate lasted him a long time, and were still intact when he was able to afford new replacements.
Welding them together whilst still fitted up to the axle and with wheel bearings adjusted snug helps to keep the flange and shaft in proper alignment, otherwise the welds or driveflange bolts will break in no time. Preloading the worn splines in the main direction of drive rotation (forward) also helps reduce the strain on the welds .
bill.

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Originally Posted by Xtreme

toc_bat is interested in above offer so ..............

Can anyone advise if the rear axles/drive flanges from a 2002 Td5 Defender are interchangable with those from a 1995 300Tdi Defender - both fitted with Salisbury diffs?

I'm pretty sure they are but it would be reassuring to have confirmation from the more knowledgable before possibly wasting toc_bat's time.

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Hi Roger,

AFAIK they should be a strait swap, the only change to Sals axles was with the change from wide to narrow hubs.

The axles from my 85 drum braked County Sals are longer than the ones from my 95 disk braked 130.

HyTuff/Maxi Drive also make versions that are longer in the hub spline that need the matching drive flanges.

I hope this helps,

A great Chrissie and New Year to all.

Tony

Thanks Tony re the axle info - And best wishes to you and your family for Christmas and the New Year. I guess those growing boys of yours really know about 'spannering' now.

BTW - we'll be staying at Merrijig on 30th April and 1st May 2012 and eating at the Hunt Club Hotel on 30th - it would be great to catch up with you again if you could find time to pop down or join us earlier in the day as done previously.

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Originally Posted by TonyC

[snip]

HyTuff/Maxi Drive also make versions that are longer in the hub spline that need the matching drive flanges.

I hope this helps,

A great Chrissie and New Year to all.

Tony

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Used to have an 'X' suffix on the part #.

Paula recommended them to me as a preferred alternative/upgrade years ago when I rang the old Maxi-Drive.