Expo Axle Swap, Rusty tube section. (Sticker Rust)

[Alex98]

So I went out and picked up an expo axle. It was a bit rusty but mostly just surface rust. However right by the sticker on the passenger side it ate a bit into the axle tubing. It's enough to be concerned about as I don't really know the axle tube thickness. It's a shame really it's really low mileage from what else I can compare it too. Everything else on it looks to be in good order. Fluid wasn't black, no pieces in housing, etc. In the deepest spot it goes down about an 1/8th of an inch. The rest of the way around it's not bad at all. I know I'm going to have to have it welded the mounts, etc. Is there anyway it can be reinforced? New axle tube pressed in? Should I even be worried about it? Forget about installing this unit?

 

[alwaysFlOoReD]

It looks to me that the rusted area is at the top of the tube, so would be in compression when loaded. I would run it. But if you're getting new perchs welded on I would also have a patch welded on top. Find a tube with the same inside diameter as the outside diameter of the expo tube and cut it in half. Round the corners to prevent stress risers when welded.

 

[Captain Ledd]

Most tubes should be about 1/4" from what I've read. Supposedly some got a bit thicker ones, but they are supposedly rare.

I've never personally cut one in half to check.

 

[adsm08]

I wouldn't worry about that strength-wise.

 

[pjtoledo]

get a small chisel and hammer, start pecking that area to be sure all the rust is "minimized" so you can see exactly how much metal is left. you'd be surprised at how much of what you think is metal will flake off. wire brushing only gets the loose stuff, it doesn't do much to deep rust.

 

[4x4junkie]

I think I read somewhere the Explorer tubes are 3/16" thick (would make sense since I found cracks on mine at the spring perches that I don't think would've happened on 1/4" thick tubes).

Agreed, you should be able to weld a cap or other reinforcement over that area to strengthen it if needed.

 

[Alex98]

Thanks for all your replies. Helped me out a ton. I got the ruff stuff kit, it's ready to get welded up.