HELP! Brand new DS front axle exploded itself after 5 miles

[-TunedDSM-]

I just put a new axle (not reman-ed) on my 97 gsx with a bolt bolt swap (it hasnt driven since the swap yet, still putting it together)

I noticed that i could not line up the carrier bearing on the 2g intermediate shaft with the bolt holes in the 6 bolt block. The bolt hole nearest the tranny bolts directly onto the block, but the farthest one threads into the actual a/c bracket. Well i accidentally cut the a/c bracket right around the 2 bolt holes (1 that holds it to the block, 1 that the carrier bearing bolts to)

Would the fact that my a/c bracket was being held on by only one bolt cause my brand new axle to do this after 5 miles:

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

 

[-TunedDSM-]

also, can you use the 1g intermediate shaft? that way i can know for a fact that the carrier bearing is secure.

 

[daves06r1]

If in the picture the axle is still bolted to the wheel bearing it looks to me something is too short or severely out of alignment like the motor and trans not sitting where it should. And yes you need to have that carrier securely fastened. In my experience the only times I have seen axles pull them selves apart is because of bent suspension,subframes,and or the motor and trans not being where it should.

 

[-TunedDSM-]

well i have a brand new DS straight control arm (OEM mitsu piece)

Brand new balljoint (obviously), brand new everything on that side. I think the carrier bearing/intermediate shaft was out of alignment

 

[BUCK]

There are differences in 95-98 Carrier Bearing Brackets - There's a lotta Threads on this if you Search "carrier bearing" even though I've seen it called Steady Bearing & yes some of the Threads you see will be talking about the Driveshaft Carrier Bearings - Believe it or not it COULD be WORSE - If you wring off in the BLOCK one of what are SUPPOSED to be 'Special Bolts" in that Bearing Housing with "shoulders" on them, etc ... You will be a LOT more miserable than you are now - Been there done that - So be sure you have the right Fasteners in that Bearing... There is a VFAQ on this for 1g's that should help too - Good Luck