2002 X axle replacement

[Kelly Hanson East]

I got back from Cuttyhunk this week and the next morning found I had trailered some portion of the 200 mile trip with no outer bearing on my left wheel - bearing buddy, nut, thrust washer, retainer were all gone.



I thank the Trailering gods for keeping the wheel in place all the way home

I skipped the last hourly inspection from Sturbridge MA due to a massive thunderstorm, everything was fine temperature wise and inspection one hour earlier.

Bad news is the threads on the spindle are badly machined and so the whole axle needs to be replaced. Looks like about 200 USD for that.

I will upgrade to SS disks I think as part of this work - another 400 or so

The correct axle looks like the 3500# 2x3 box axle, from Champion

One thing I dont like the look of is the springs appear to be welded on to my axle

more to come

[Kelly Hanson East]

Just ordered replacement axle

Champion XATS35X with hub measurement 87 inches and spring center 68 inches from Champion

Its a 2x3 inch rectangular axle, with axle over spring design

250 USD with expedited shipping, 7 day delivery

[Kelly Hanson East]

Update - it took me two hours of pretty heavy labour to get the axle off this morning.

I have a depart date for the Cape of Aug 16, but now I know Ill make it since worst case Ill give the axle to my local mechanic and have him put it back together, so Im a week away plus a check to being back on the road. Still hope to do it myself and save the bucks.

Removal notes

My strategy is to drop the entire axle and get it out from under the boat and trailer for replacement of beam and upgrade to disc brakes.

You need 13/16 inch and 7/8 sockets and box end wrenches. You need good ones, not cheapies. Buy 1/2 drive,6 pt name brand sockets. If you turn off those rusty nuts and bolts underneath your boat, you will spend a lot more time than two hours. Good sockets will have the 1/2 drive hole broached off-symmetry with the hex pattern which will give you a range of angles you can use the nuts with a 24 inch breaker bar. Two of them took all my strength to crack the threads, and I had to work hard to back off the first 5 turns. Im not a weightlifter but can one-arm push-up with either arm, so im not weak either.
You have to maneuver the box end onto the four nuts on the hanger bolts so that you can then twist off the nuts from the outside. Once you get through the worst 3-4 turns, you can put an extender on the breaker bar and move outside the fender and things get easier. Make sure you apply pure torque still, when using an extender bar...DONT round off those nuts and bolts!!

Im going to burn off the U-bolts with oxy and replace.

Ill have some spare drum brake parts left over when I am done with this job....will post up here when done. If anyone needs something quickly let me know by em.

[Kelly Hanson East]

Well - all the parts arrived from Champion today, 7 calender days from ordering.....with luck Ill be back on road on Monday...incredible..

[Kelly Hanson East]

Last notes - it went as smooth as silk - 90 minutes to get the axle back on. I bled the brakes using a screwdriver to push the piston in from the front and push pure fluid out of each caliper. Technically you should pressurise the system, then open the bleed screw to help get air out but the Kodiaks put the bleed screw at the high point of the caliper so air works out quickly. The MC was nice and clean, but Ive been pushing new brake fluid through it at the start of each season, so that paid off.

On the disc brake conversion, remember you have to remove the residual pressure valve from the master cylinder (you need it for drum brakes, must NOT have it for disc brakes)

The Kodiaks stop real nice and showed no corrosion after the salt water dunk plus sitting for 8 days. The boat stops really nicely too. One of my tires is dry rotted though and is losing air slowly (weeks) so the boat budget never ends.

[R Rae]

Well done Stephen.

Just to let you know, I am posting copies of this awesome blow by blow encounter above the galley in the ol'
X.
Who knows?...........Maybe my turn is coming soon.

Thanks again..............R