So I had some issues with the front end recently and have yet to get it all sorted out. On a 300 mile trip back home I had a hub start to go. After finally getting the axle nut loose I replaced the bad hub. As I backed out of the driveway it broke the brand new hub. So I pulled the axles out of the front and plugged the axle housings. Basically making it 2 wheel drive. I actually bought some 2" rubber expandable plugs similar to the rubber freeze plugs. The reason I did this was because I thought maybe the axle bound up on the ball joint. So on the second hub I bought, (which was more expensive, better quality) I had nothing to put any pressure on the bearing. I backed out of the drive and it busted again.
I'm at a loss....
I'm open for any suggestions.

Just FYI, I pressed the wheel studs in and made sure they were seated and no pressure was put on the bearing. It seemed to snap both times while backing up with the wheel cut hard and hitting the break to go into drive. I checked all my bolts for proper torque. Any ideas? I'm stuck and I need my truck back.

 

The center axle nut needs to be torqued while operating (driving) or pressing out of the knuckle. Pretty darn tight I forget the ft-lbs but I weigh 260 and I usually give a slight bounce on a 18" breaker bar to set it. Don't drive it without the axle stub shaft installed.

Make sure the threads and splines of the stub shaft aren't preventing the nut from being tightened completely, I've personally destroyed the threads on 2 different trucks just taking the nut off.

 

I was thinking about that the first time but not sure how that would hold anything since the axles can be pulled right out of the housing? The torque spec is 170 or 180 for the axle nut. Like you mentioned I stripped both sides taking them off. I need new u joints in the left axle and now the threads are stripped. I'm thinking I'll order the ends of the shafts and press them apart and install new u joints on both sides. Just to note the first new hub I installed I did put the axle back in place. The shafts was seated correctly and the castle nut was torqued down.

I'm not trying to argue your point by the way, just wondering how that would make a difference since the axles float? Oh and I installed a new rotor just to add to my list. Thanks for the reply.

 

That actually just hit me when I asked you that... Does the shoulder of the axle end press against the back of the hub creating pressure between it and the castle nut to hold the hub together and help cover for dust?

 

Yes it holds the bearing together. Not sure why it came apart the first time, maybe it wasn't seated all the way?

On a side note I was able to get the threads repaired at a machine shop once when I needed the truck asap.

 

I was planning on taking them to the machine shop today but thought since the u joints need to be changed I'd go ahead and get new ends. The side the had the hub problem had significant thread damage where it had slack I guess. It took a 10' pipe and breaker bar the whole way off which ruined the rest of the threads. That same side had the ball joints replaced before I bought it and it must have been just loose enough to ruin it. Thanks for the slap in the back of the head, I needed that. Very expensive mistake.