Project Pickle - front axle overhaul (part 17)

There were some subtle hints, almost indiscernible signs on that front axle... who am I kidding: There was red RTV on the free wheel hubs and one of the dials didn't move at all. 

 Just in order to get an idea of the state of affairs and because I would have to do it later anyway, should I have to dig in any further, I decided to drain the oil from the axle.

 DID I DECIDE TO DRAIN THE OIL FROM THE AXLE. 

 (In the end I welded a large nut to the filler plug in order to open it and then drained the oil.) The mere fact that the wheelbearing nut wasn't even finger tight probably surprises no one at this point?

Also RTV is clearly the solution, when you actually have leaky axle seals and the oil-grease mix is leaking out of the hubs. 

Be overjoyed for the lack of smell-o-vision. 

Despite the look, the UJ cleaned up nicely (and so did all the other mucky bits), but it was obvious that water got in and did its thing. 

 Surprisingly the kingpin-bearings didn't have any excessive play and could probably have been reused. 

Once cleaned things started to look decidedly better. 

 The wheel bearings were definitely shot.

... and because they were so shot, the axles wore out the actual axle support, which in turn caused the leaky axle seal.

Even though I am well aware that the axle housings will be rusty again at some point, a lick o' paint goes a long way in making stuff look nicer.

 

One of the weird fails prior to the overhaul was a failed star-washer, which probably caused the locknut to come loose at some point. Also the cheap aftermarket ones had a tang which was too wide and wouldn't properly engage with the cut out in the axle. 

In order to get the little circlip in, the axle stub has to be pulled out - turns out that's what the little M8-thread in the end is for.

And that's the front axle overhaul done. Probably the most difficult thing to do was to get the green rubber seals over the balls, which involved putting the wooden handle from my hammer through one of the kingpin bearing seats and levering it over with two small tire irons.