FAD axle broken line up pin

[Lizardman]

Pulled the the front axles from my Rubicon with FAD today and found this issue. Appears the line up pin is broken off the outer shaft. And the bushing is damaged on the inner shaft. That’s what destroyed the seal. Is my observation correct? If so should I replace them with new axles or do a FAD delete with a solid axle? This happened when this jeep was involved in a collision broke the knuckle off. Thanks

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[grimmjeeper]

You do need to replace the shafts, no question.

Whether you do a FAD delete or not is up to you.

 

[Fish]

Do you off-road? = fad delete. Do you daily drive and don’t offroad. Keep fad

 

[Lizardman]

Not my daily but does do about 75% pavement driving. Probably should keep the fad I guess.

 

[Fish]

Not my daily but does do about 75% pavement driving. Probably should keep the fad I guess.

Mines deleted because it’s a off-roader, and I trailer it to the trails. Rarely gets driven on road.

 

[Lizardman]

What axle or delete kit did you go with?

 

[Fish]

What axle or delete kit did you go with?

They’re chromoly Yukons

 

[grimmjeeper]

What axle or delete kit did you go with?

I have RCV shafts with the FAD because I drive mine to and from the trails. They're not cheap but I do like the CVs when I'm in 4wd.

 

[WillysMeow]

My 2025 Willys came FAD deleted from factory, I daily drive and Rubicon trail etc.

Replace it with one piece chrome-moly axles or RCVs.

 

[VTJL23]

Pulled the the front axles from my Rubicon with FAD today and found this issue. Appears the line up pin is broken off the outer shaft. And the bushing is damaged on the inner shaft. That’s what destroyed the seal. Is my observation correct? If so should I replace them with new axles or do a FAD delete with a solid axle? This happened when this jeep was involved in a collision broke the knuckle off. Thanks

Yukon FAD with chromoly axles...

 

[VTJL23]

Yukon FAD kit with chromoly axles... you provide a prime examlple why Jeep has abandoned the FAD....

 

[wibornz]

Pulled the the front axles from my Rubicon with FAD today and found this issue. Appears the line up pin is broken off the outer shaft. And the bushing is damaged on the inner shaft. That’s what destroyed the seal. Is my observation correct? If so should I replace them with new axles or do a FAD delete with a solid axle? This happened when this jeep was involved in a collision broke the knuckle off. Thanks

I hate to be the bearer of bad news, but If it was hit hard enough to damage the axle shaft, I would say the axle housing is now junk and you need a new front axle. You will not be able to see the damage to the axle housing, It will have to be measured to see if it is still true and straight. The axle housing had to flex like crazy to break the axle shaft like that. I would have the axle housing checked to ensure that it was not also damaged in the accident. Th only way for that pin to be sheared off is for it to be flexed hard enough to sheer the pin. The pin does not carry or support weight nor should it have any load that would cause this failure. The pin is used for axle alignment and should not be bearing sufficient weight to break.

Changing the axle shaft at this point might be throwing money at something that is not the core problem.

 

[Maverick909]

i second that the axle housing needs a deep inspection. Im gonna say a new complete axle is the best route here. i would also be fine tooth combing the frame at the crumble zones

 

[Remorseless]

I'll third that - I'd be shocked if it broke the knuckle and the axle shaft with zero damage to the housing. Even if it just deflected things enough to cause the ring gear to chew stuff up, I'm willing to bet there's at least some damage to that housing.

 

[grimmjeeper]

When I wrote my first response, I missed reading the last sentence about the broken knuckle.

Definitely agree it's likely there is more damage to the axle housing and it needs to be checked.

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