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I am by no stretch a metalurgist, but I figure it probably just broke due to either being really stuck badly, or some other failure down the line......I doubt much more than that. You have to remember that a young low-ranking member of the armed forces operated this truck and without much...

Saddamsnightmare, actually as we speak, SETOYOTA is removing the broken axle in question and having a metalurgical sample removed to send to the word renowned "Axle Failure Institute" in Switzerland. It is supected that the forging process in the plant where this truck was manufactured was...

Yep, climbed up on the broken portion and forced its way out the cap.....now, what caused it?

As Recovery 4X4 mentioned, there could have been an axle issue that caused the breakage. I'm thinking an axle that didn't disengage, then someone drove it around on asphalt, breaking the end off the axle stub shaft.

Here's a couple pics: You can see how big the axle shaft u-joint cage is and how it'd be hard for it to move outward. You can also see in the lower pic the inner seal in the seal holder/thrust washer.

In the case of the Rockwell its a bit different as the knuckle and wheel bearings aren't isolated from one another. The seal keeping the diff oil from the knuckle is on the inside of the knuckle in the axle tube. There isn't any need to keep the spindle sealed in that case. Also, the axle...

There isn't a seal in the back of the spindle, only a thrust surface for the front of the joint to run against and control the end play. There is a bushing inside the spindle as well, but it only keeps the axle centered in the spindle and the cap takes care of the other end. On the axle tube...

I think the tip of the stub shaft is broken off and got pushed out. If all is as normal in the knuckle, the spindle holds the shaft in place and keeps it from coming out any at all. The only way the shaft could come out that far is if the spindle was worn so badly as to allow the axle to...