Newly installed Aisin hubs breakage.
 

I got a pair of aisin hubs to replace the crappy Mile Marker ones on my ADD 96 T100. The hubs were cleaned and regreased.

I installed one without a hitch. oday I installed the other hub on the drivers side and ran into a huge issue. I removed the mile marker hub cleaned the surface and placed the new gasket on the wheel hub. I then installed the hub body, cone washers, washers then nuts and torqued them to 23lbs. I then installed the gold bolt and torqued it to 11lbs. I did notice something strange at this point which was the cv shaft would not spin (tire on, truck on ground)... I didn't think it was a big deal and figured i should complete the install and see if it fixed itself. i then installed the star gasket, face and bolts and washers. Torqued each face bolt to 11lbs. I then jacked the truck up to test the wheel and hub. I spun the wheel while the hub was in the free position and the cv shaft was spinning with the tire....not good. i then locked the hub and as it should the cv shaft spun with the tire. I set to free and still the cv shaft spun with the tire... I was stumped and decided to pull the hub off and see what is up. When I got the hub off I found the issue. The hub's back washer was crumbled and it was causing the hub to stay locked.
It looks like its the "washer" that goes around the outside of the spindle gear. It looks like pressure from the "c ring" snapped off the outer portion of the washer. The only place on the washer that was not broken was the opening on c ring. The debris see is actually the broken parts of the washer.

The last pic is the best shot of the breakage. Is this something that can be fixed? It just started to rain. If it stops raining this weekend I will pull the MM hub off and recheck the spindle area for possible causes of the failure. Could it have failed from wear and age?



Here are the photos i took of my hub when it came off.
http://tinypic.com/r/sdhi54/4
http://tinypic.com/r/rubnyg/4
http://tinypic.com/r/2dlpsoo/4
http://tinypic.com/r/2rnzacg/4
http://tinypic.com/r/27ybgqq/4
http://tinypic.com/r/2wc3d38/4
http://tinypic.com/r/10zbvwp/4

Busted hub gear. Remove and replace.

:guitar:

Any idea on how these broke?

My bet is whomever disassembled them last time broke that lip when they put the clip on the hub gear.

:guitar:

http://www.longfieldsuperaxles.com/

Never have to worry about breaking them again.

Thanks TC and Wab. I was trying to figure out if the failure was on the spindle/truck or the hub. When I first got the hubs they looked like nothing was broken and the inner gear (that is broke) rotated like it should, now it doesn't. I am going to pull the working hub off the pass side and try it on the driver's side.