Rear axle shaft thread broken

Andy, It sounds like you have a good plan. To help cut the threads in the home made nut you might try tapping it first with a 9/16-18 tap.

Joe CB, Below is the advice from Fastenal. They are the experts and have done lots of tests of bolts and nuts.
 

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The only negative is that the nut for that axle will be different from any other and must not be mixed.
Click to expand...
Yes, well, the "self-made nut" will certainly be visually different from the others, which makes it difficult to confuse them. I will know the problem, there will be no sale of the car in the foreseeable future, so there shouldn't be anyone confusing the nuts.

To help cut the threads in the home made nut you might try tapping it first with a 9 / 16-18 tap.
Click to expand...
You mean, so that you first have a guide where the lathe tool goes? I don't know if that's necessary. It's actually just a matter of setting the lathe. The feed is set to 18 turns per inch and then turned 1 / 100mm out until the test mandrel fits. But I can certainly address the issue.

Thanks to everyone.

Greetings Andy
 
Soooo, yesterday I got back under the car and took care of the brakes, and then I looked at the thread of the axle shaft.

In the meantime the thread cutting tool has also been delivered. I sawed that in at the original notch. A slot of approx. 1.5mm!
Schneideisen1.jpg


This can now be pressed together in the die holder.


Schneideisen2.jpg


Originally the thread has an outside diameter of 15.875mm. In three work steps I set the die tighter and tighter and cut the thread. In the third step, the slot in the die was completely pressed together. After the last cutting process, the outer thread diameter is now 15.2mm.

A test thread / test mandrel is now cut with this die setting.

I also got hexagonal steel. Wrench size 24mm, grade 42CrMo4V. This could be tightened with an M16 thread with 230Nm. Much more than necessary, but stable enough to ensure safety. A new castle nut with a new diameter was then made from this steel on the lathe. The correct fit is then checked on the test mandrel.

Greetings Andy
 
Soooo, it took long enough.

The Ford has been driving again since yesterday. Here are the desired pictures of the new nut.

Mutter1.jpg


The thread of the nut was cut very tightly on the lathe. Too short. I had to cut the thread of the axle shaft again with an even tighter die setting. But then the nut worked. This was then tightened with a torque wrench. Then the position of the axle hole for the split pin was marked and worked out with a cut-off grinder. Then everything was put back together and secured with the cotter pin. Now the car is running again.

Mutter2.jpg


Thanks to all readers and tipsters!

Greetings from Berlin

Andy
 
GRutter:
that was a great video you shared.
There is always another way to do things if you think about it.
Thanks for sharing.
 
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