We headed out to Rocker Panel Pass here in AZ, which has a pretty gnarly section of the trail. I was easing up onto the first obstacle and *BANG*, my driver's side front axle (short side) sheared. I'm surprised the short side went and not the long. This short side shaft was the HD short side shaft out of a '74 K5. I think I must have weakened it sometime in the past.

Took it apart when I got home and found the axle sheared clean off where it exits the differential. Pulled the remaining chunk of splined axle out with a magnetic retrieval tool. So, I made a nice paperweight.

I need to source some trail spares now. Spare inners and outers, fully assembled would have made for an easy 20 minute repair if I had the parts with me.

I'll get some photos up later tonight when I get my camera batteries charged.

I'm surprised the axle lasted this long. Its been wheeled for 2 years now.

So, first Stone, then mine.. who's next?

long sides are less prone to breaking because the added length allows more deflection.

get a set of longfield axles and u joints. lives an hour from me, and makes great stuff. he's running a special on 300m joints right now

nice. his web site lists the u joints for $130 each. Cheaper than CTMs for sure.

As for axles, I need a mixed set for my axle. Ford Bronco inners with Chevy outers. Need to find some place that will sell them individually or mixed application.

bobby has the best customer service i have ever encountered. he loves the garage builders out there too, so id imagine if you called up and told him what you were running and stuff, he could definately put together a package for you

I'd like a set of chromolys, but I think I'll hit up the local JYs here and see what I can get a few axle shafts for. Then I'll pick up a spare long side bronco inner and put together a spare set of axles for the trail.

This one lasted me over 2 years of hard wheeling, so if I can put together a whole set of spare axles and replace the one I have, I'll be set.

and if you are running 33"-35" and not going bigger, you could get away with stockers.

Datz, are u running 33's still? or did you go up to 35s? I busted my pass. side axleshaft the very 1st time I took it off-road after my SAS! To say the least, I was pretty pissed! I was running 35s, and a LOT of the skinny pedal, then boom. I then used stock axleshafts while welding the caps in and never had a problem w/ those. Even though I never had a problem w/ the second set of stock axleshafts, I upgraded to the chromos when I went to 37s just for the extra insurance and peace of mind. Later...

Ouch! The good news is there are probably lots of that combination in the junkyards.

Yep, still running 33s. Planning on 35s eventually, as the 33s are really too small anymore.

i broke my outer axle shaft one of my first times out and they were 20% stronger than stock not chromos now i hav chromos and that was on 33's it broke in a very weird spot to but i was really flogging it

try here John:
http://completeoffroad.com/wsm/c-85_dana_44.html

Robert, wow.. great link. Thanks!! The prices are reasonable too.

Finally got some new batteries for my camera, so I'll get some photos tonight for you all. The break is so clean that it looks like a machined surface.

Serious question: If you put in super strong axle shafts and U joints and they are no longer the weakest link - then what is?

I'm just wondering if it might not be beter to have something easily replaceable like the axle shafts be the fuse - rather than something that is tougher to fix.

Probably hubs.