Wow! I can only guess here, but you should check to see if the housing is bent.

 

Did you get the entire axle assembly replaced or just the axle shaft? If I had something like that happen I would get the entire axle assembly change because who knows how much interior damage had been done to the axle shaft housing.

 

I only replaced the shaft. I see a few options for replacements, how can I tell what I have?

 

Where are you located?

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Do you have a 2WD or 4WD? Do you know if the rear diff is stock? Where did the axle break (near splines (inner), middle, or outer? Any pictures of the broken axle? When you got the new axle, did you do the install or did a shop? Did the axle come with the bearing and seals already installed? When you noticed your seal leaking was it a lot, do you think there was any fluid left in there?

I'm no expert and there's lots of guys on here much smarter than I. This is info I've gathered from reading while my Titan rest on jack stands awaiting repairs. I'm rebuilding my rear end right now, just dropped off the axles at my local machine shop to have new seals/bearings installed.

2WD has the same length axles. 4WD the passenger is about 7/8" longer. If you've had a trutrac installed with 4WD and either the axle or carrier weren't properly shimmed then this could have led to a problem, perhaps the axle broke then your bearing ate itself. The bearings should be pressed on such that a .0015" feeler doesn't fit between axle shaft bearing cup and seat. If this was off, could have led to axle seal leak, bearing wear, etc. (Complete speculation).

I would for sure do a thorough inspection on the housing. Seems like it would take quite a bit to bend the housing, but I suppose the first axle breaking could cause some internal damage. I'd be leaning toward what HRTKD said with maybe getting a whole new axle housing assembly, but your looking at big bucks. Maybe you can get lucky and pull one of a junked one, if you can find one. If I went with another axle, I would also do a good inspection of the diff and make sure there no metal pieces in there.

 

Thanks for the replies. I'm in Salt Lake City Utah. It's 4wd, don't know if it's stock (bought used). Had a shop do the install, axle came with bearing. There was still oil in it, still leaking. I'll try to upload a pic.

 

thats such a clean break. is there a weld at that location?

 

I can hit up my buddy for a full brand new axle if you are willing to drive over to socal. I need to get price but it will be cheaper then buying from stealership

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Can he get one of the upgraded '08 axles? For the right price I can make the drive.
Thanks-
-Jim

 

That's the kind of break you get when a hardened shaft is being flexed constantly, I think the tube is bent. Might be time for a complete axle assembly.

 

I just hit him up, he will let me know soon.

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There's obviously something wrong with the housing or somehow they were not installed correctly.

 

Just curious how you were able to remove the snapped axle. I just had the same thing happen and I am trying to figure out how to remove it. It snapped right at the bearing from the bearing failing, overheating and weakening the axle.

 

Once you remove the bearing axle assembly if it broke like this you should be able to stick some good long nose alligator pliers in the rearend axle tube and pull the rest of the shaft out, the axles don't have c-clips like a Chevy.

 

Late follow up, but as some suggested it was indeed a bent housing, causing the bearing to wear out very fast and then cut through the axle. Found a local place with a used housing (they've done this before) and it's been fine ever since. As to the current question, I had a shop do it, so not positive how they got it out but I believe it just falls out at that point.
Thanks all-
-Jim