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Technical Rear axle woes

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Technical Rear axle woes

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AAB1992

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Hello all,

Having had a through yearly inspection of my axle on a 2004 plate with 132k, I've found some worrying corrosion and a small hole! I do have a spare axle that has some very light corrosion but don't really have time to fit it or refurb it yet. I'd look at fitting it next year.

My question is, the pin sized hole where the springs sit, does it have to be welded or can it be just filled with metal epoxy etc to get it through another year? The welds are strong, and the metal is thicker near the welds, so snapping shouldn't be an issue.

What are your thoughts?

Adam IMG_1473665754.100360.jpgIMG_1473665769.129907.jpg
 
Personally I'd leave it. Just remove as much rust as you can, and treat it with your favoured corrosion proofer.

IMO trying to weld it will likely do more harm than good and using fillers just risks trapping moisture and allowing the corrosion to continue underneath. Plus, MOT testers are quite rightly suspicious of filler in structural areas.

Another idea might be to drill it out a little to enlarge it, so that it becomes a drain hole at the lowest point in the spring cup. A lot depends on how much metal is left once it's been cleaned up. Whatever you do, I'd suggest at least removing the springs to clean that area properly.

I'm wondering how long it will be before we see a similar thread in the 500 section. For early 500 owners facing this problem, the upgrade to a later type beam from a salvage car would appear to be a no-brainer.

From what I've seen recently, and from looking at my own cars, I'd say these beams have about a ten year life in the UK climate unless caught early enough to properly corrosion proof.
 
Last edited:
jrkitching said:
Personally I'd leave it. Just remove as much rust as you can, and treat it with your favoured corrosion proofer.

IMO trying to weld it will likely do more harm than good and using fillers just risks trapping moisture and allowing the corrosion to continue underneath. Plus, MOT testers are quite rightly suspicious of filler in structural areas.

Another idea might be to drill it out a little to enlarge it, so that it becomes a drain hole at the lowest point in the spring cup. A lot depends on how much metal is left once it's been cleaned up. Whatever you do, I'd suggest at least removing the springs to clean that area properly.

I'm wondering how long it will be before we see a similar thread in the 500 section. For early 500 owners facing this problem, the upgrade to a later type beam from a salvage car would appear to be a no-brainer.
Click to expand...

Thanks for the input there; I like the idea of a drain hole. The rest looks to be reasonably strong, but rust is always worse than you originally think.

I was quite shocked to find that hole, the rest of the car 99% percent rust free and the car is subject to yearly waxoyl/inspection.

I think the yearly layer upon layer has not done the axle any favours as I did find some moisture under the layers. Do you recommend a different approach with axle, like a thin spray of something as opposed to a thick layer of rust proof?

I’ll remove the spring so I can do a proper job.

500’s will end up exactly the same soon as they pass the 8 years mark. I’d happily fit a 500 axle but I’m worried the extra 2 inches would make tracking more difficult.
 
Its unlikely to be a drain hole but you never know someone might have had the forethought to drill one. To do a proper job it would need to be at the inner side of the pan where it sits lowest.

The spring pans rust because the springs rub away at the surface so there's always bare metal to eat into. The front side walls to be worst about 20 to 40mm from the weld. I believe that's stress corrosion - more stress in that area accelerates corrosion.

The only sure way with a badly rusted axle is welding or replacement. All that depends on the condition of the car generally. In the meantime treat with ACF-50 and then Waxoyl or similar water displacing wax.

I replaced my axle at a total cost of under £200 and I still have the original to sell. I intend to grit blast and paint or maybe zinc metal sprayed.
 
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