Rear axle repair

We start to disassemble rear axle. First residual oil is poured out, and then drive shafts are disconnected. Both are usable, just bearings are breathing out acoustic signals of deterioration.

Components of the rear braking system are in much worse technical condition comparing to the front counterparts. Braking cylinders are completely stuck by rust, braking pads are separated from braking shoes.

Handbrake wire is rusted and broken, but wheel mechanisms are restorable.

Seems car has been moved without rear springs on own wheels quite a long distance, so against road surface is ground away big part of pivot housing, as well as greasing nipple. Even intermediate shims are partly chiselled against the ground - these parts must be replaced since respective working surface is damaged.

Most probably at the same time also main gear housing is damaged by driveshaft which has been positioned at unacceptably wrong angle. We shall weld those cast iron pieces back in place to save this expensive part.   

 In spite of muddy oil residuals found in the main gear housing gears are without signs of unacceptable wear, just bearings again are worrying. When carefully cleaned main gear parts are appearing in pretty good condition. As for other technical units, bearings and seal rings are among necessary replacement parts.

Rear axle drive shafts are without damages, just rust cleaning and fresh paint shall be applied to the flanges.

More detailed investigation of the wheel braking cylinders shows that our first conclusion has been correct - it is not possible to recover all these items because of severe corrosion.

As long as all assembly units have been dismantled we start to prepare all parts for further treatment procedures. There are welded on iron main gearbox housing both fragments. Weld surface is machined to get at needed smoothness. When this is done housing is going to external surface sand blasting.

Cleaned parts are sent for further surface treatment - powder coating or galvanizing. As joint surfaces are protected suspension components are sent to powder painting.

Main gear housing as well as braking system base components are powder coated as well.

Rear axle assembly starts with preparations - all threads and mates are checked and cleaned to ensure smooth assembly process of this valuable component. During assembly all new gaskets, sealings, bearings and rubber parts will be used.

Wheels are cleaned and prepared for painting and following tyre installation. Open issue is just spare wheel - it is needed to find missing wheel with the same kind of cap locks.

Using received new bearings, seals and gaskets we start main gear assembly.During assembly manufacturer's instructions are followed and all needed adjustments are carried out accordingly.

Before right side housing of the swing axle is installed universal joint is put into place.As both halves are attached together braking system components - cylinders and pipelines - are fixed in place.

Assembling of restored rear axle is finished by installation of original central boot over the slip universal joint using restored original clamps.