1993 Bounder with broken axle twice in 2000 miles

77rollalong wrote:
what Jack a$$ would weld an axle shaft? would be the last time i would be going back there...

This!
Take the first guy to small claims. What he did was inexcusable! I would have everything checked inside as well. If the axle wasn't straight after welded, ther will be other damage.

dana32159 wrote:
The original mechanic had to replace the entire hub and part of the axle housing when he installed the welded axle back in November.

Can't help but feel like I should go after the first mechanic for installing an axle that he knew might not hold with a weld which really put our lives in danger.

As much as I think the original repair was poorly done and causing continued problems I would not waste my time going back.

I hope the current shop is good and sets you on the right path. I hope it is a real heavy line transmission/axle shop that knows how to set the gears, pinion seal etc. If they are good I would be tempted to rebuild the entire axle assembly.

what Jack a$$ would weld an axle shaft? would be the last time i would be going back there...

Have the fluid changed if they didn't do that with the latest axle replacement. Some welding slag would be bad for bearings, gears and seals. Not saying for sure that's happened, but from your description of the weld it seems possible they didn't clean it up...

I had the rig towed to a mechanic who told me that the axle broke in the same place as it did in November. The axle, which I thought had been repaired with a replacement axle in November by the first mechanic, was instead welded. So it was a miracle that the weld held for several hundred miles, as I looked at it and saw that it wasn't even a good weld as it didn't appear to have penetrated on 1/2 the axle.

The second mechanic fortunately had a used axle that he replaced and today as I was driving it back home, I noticed that fluid was leaking from the differential. When I called the second mechanic, he said he thought it might be the pinion seal and he never touched that in his axle replacement. So now I've left it at another mechanic and explained the problem to him. Any suggestions as to why there is leakage? The original mechanic had to replace the entire hub and part of the axle housing when he installed the welded axle back in November.

Can't help but feel like I should go after the first mechanic for installing an axle that he knew might not hold with a weld which really put our lives in danger.

Even a 25 year old coach shouldn’t be breaking axels. Find another repair shop.

I don't have any answers until it is towed to get repaired tomorrow. The previous replacement axle was a new axle for a Chevy truck installed in November. I don't know if that's the one that broke or if it's on the other side.

Not enough info to even think about it!

if its breaking the half shaft, i would be checking the axle housing to make sure its not bent, as that would cause strain on the half shaft, and there is no weight on the half shaft only the torque, or the half shaft is over hardened, maybe have them try reversing the half shafts, and see if it breaks the same side again, if so then the axle is bent..

Something is very wrong.
First thing I would check is to make sure the housing isn't bent.