I had a rear axle nut back off a few months ago, severing the cotter pin in the process.

Found the splines to be hammered and twisted.

The hub, which normally should slide easily on/off, required serious convincing every mm of the way off.

I did not consider attempting to rebuild, instead used one of several complete housings which I pulled off junkyard vanagons many moons ago at about 30$ each.

________________________________
 From: Jeff Lincoln <magikvw@GMAIL.COM>
To: vanagon@GERRY.VANAGON.COM
Sent: Tuesday, August 14, 2012 7:08 AM
Subject: Re: Road Story to share

Dennis,

You are absolutely correct. The wheel did fall off last fall. I replaced
the axle shaft, bearings, and backing plate as a result. I suspect the nut
was not tightened sufficiently at that time and this is the result.

I took it to a shop yesterday and they couldn't find a socket large enough
to tighten it properly either (nice) - they got it a lot tighter than it
was an put a proper pin in it. The plan now is to take it to the place I
should have taken it to in the first place - I trust them and they do car
and truck/heavy equipment repair - they will have the right tools.

I am not trying to be dumb I just want to make sure I understand you - when
you speak of the wheel flange are you referring to what I call the "hub"
(the part the wheel bolts to)? I didn't replace that after the original
incident and I wonder if that also contributed.

What are the acceptable measurements of the splines on the axle shaft?

Even with that nut tightened more (not properly) there is a significant
rumble back there still. Is there a possibility that this situation ruined
the new bearings that were just installed? There doesn't seem to be any
significant play in the wheel side to side or top to bottom.

I greatly appreciate you sharing your knowledge.

Thanks,

Jeff