So, my driver side (front) axle shaft needs to be replaced since the boot is torn and its already too late to only replace the boot. I found a part-out MR with 58k miles and bought the used axle shaft from the guy but while he was removing it, he damaged the threading on the axle. Here are the pictures of the thread damage:





He only had me pay $50 instead of the original asking price of $150.

Is this something I can fix easily? Or is it useless?

If it is useless, do you suggest I get my current one re-built or just bite the bullet and buy it brand new?


Thanks for the help


p.s. Forgot to mention, he said he couldn't get the hub off. I don't know if that's something I should worry about. Or did he just not know how?

 

He hit the end with a hammer for sure. The only way around getting a new axle is to take a hacksaw or equivalent tool and cut the end about two threads in. Re-threading the axle won't help at all.

 

So you think it will be ok and safe if i just shorten the thread? And you said 2 threads in, but it looks like its 4 thread lines that are bad. Thanks!

 

Grind the high spots down and re-thread with a thread chaser. Shade tree you could just file down the high spots then clean the threads with a triangle file, but that takes a while.

No way this warrants not being able to use this axle.

 

From the amount of rust on there...no surprise he couldn't get the hub off and probably why he was hammering the **** out of it....I replaced both front hubs on my 2003 Evo 8 and they simply popped right on out with little to no pressure...

 

But that can be fixed, right?

 

I certainly wouldnt use it. Not when you can get a used one for 175.
Do not cut it down. Then the cotter pin will be useless.
And Im surprised another technician told you to file down the high spots. tisk.
Good luck doing that and getting the tap on correctly. Do not half-as s your evo, nor your safety.

 

It can be fixed. Going to have to take it to a competent mechanic. Might not be worth the price though.

 

Like nightwalker previously said, it might not be worth it....price it out and see what a competent mechanic says he can or cannot do.....

 

When you put the axle in, put some anti-seize where the axle meets the hub. Then you wont have to John Henry it if you ever need to take it out yourself.

 

i too am amazed at people suggesting to cut it down. i told the OP that would make the cotter pin useless, too. I literally told them everything you said. lol

However, it's certainly worth the price the OP paid, considering the threads can simply be taken to a grinder as those 2-3 damaged threads are not necessary. The nut will be behind the cotter pin hole. So unless i'm missing something, they're unnecessary. I asked a few other people whom all suggested filing/grinding the end into a smaller, slightly tapered shape. Chamfer comes to mind.

 

I have had to fix this type of thing before. other shops or friends trying to save a few bucks.... anyway

I typically just file down the damaged areas in that one spot. Also the Chamfer will work too.

 

he hit the **** out of that thing with a hammer, I would just get another one. Theres really no way of fixing it other than cutting it. If you do you will not be able to put the cotter pin that locks the nut in place.

 

Tapering it down might allow the nut to begin to thread on the good thread still left.

 

I've been working on cars for 34 years. They make a thread chaser kit just for this repair. I've probably fixed a couple dozen axles exactly like I've described.

Throw away your money if you'd like.

If he was in my area I would say bring it by my shop and I'll fix it for free. It would take about 5 minutes. If you are friends with any local mechanics, which you should be if you own an Evo, then they would probably do the same.