Broken CV axle

[itburnz]

Hey!

I've got an '86 FWD Corolla with the 4-ALC engine and 3-speed tranny with bolted on differential. I always had a rattling noise when driving on the highway and a hideous clunking sound when hitting a pot-hole or going hard on the corners. I think I figured out what caused that... When I stepped on the brake recently my passenger-side drive-axle broke and left me stranded.

I checked my Haynes manual on how to replace the drive axles and it seems straight fwd enough for me to do that. However, the axle is bolted onto something the manual refers to as a side gear shaft, which sits in the differential. There are studs on this piece that bolt onto the drive axle. The studs got bend and thus the drive axle simply fell off (the bolts must've loosened w/o me recognizing it).

I'd assume that I could simply replace that piece and bolt it onto the drive axle after I cleaned the CV joint and greased it again. If the CV joints are shot and noisy I could still do them later then. Just trying to save a buck... Well, the car has ~140k miles and I suppose the CV joints have never been changed. It may be that time anyway. BTW the differential doesn't seem to have suffered - the gear shaft thing spins nicely on both sides - it's just not hooked up to the wheels anymore.

I have a few questions for you guys:

1) I couldn't find a replacement side gear shaft as of now. Does it go under a different name? I wouldn't like to be considered an idiot at the parts store again...
2) It really seems that the studs of the side gear thing are simply bend. So, couldn't I simply take it out, give it to a machine shop and let them replace the studs and then screw everything back together?
3) When I go through the online catalogs of various car parts retailers I always find a splined CV axle that supposedly fits my vehicle, too. Does anyone know if I could just abandon the bolted 2-piece assembly and replace it for a splined 1-piece one? The latter seems a bit better to me, but I can't tell if it fits since I have to buy it before I can compare it to my set-up.

Let me know if you need clarification on something I have said - hope it makes sense. Thanks!

[itburnz]

I actually just had another look at the car and have some additional info to go along with my earlier post. The gear shaft that sits in the differential can be turned easily by hand when the transmission is in neutral. There's some play in all directions though. Is that what it is supposed to be like in neutral? When I rotate it by hand I can't feel any resistance, so that I'd think the differential is OK. I can't just pull the gear shaft out, so that the snap ring still holds it in place. The guy who towed the car home said that I'd have spilled all the differential fluid if the diff was broken. I can't see any traces of leakage.

Regarding the studs holding the axle on: I was able to get the last straight one out by hand. I think I could replace all the studs myself actually.

[uraverageyota]

Sounds like you've got an easy fix. I also have an 86 corolla le, I replaced both front axles yrs ago when I purchased the car. Very easy job to do, those side gear shafts which stay in the diff are just about bulletproof, as long as you didn't egg out the bolt holes in them you should be good. If you've still got the lockwashers make sure you put them back in.