Hey guys, I have a question in part with my brother.
some details - 03 jeep TJ - solid axle ind. built him some Dana 44's with some ARB's and gears 32 spline shafts.

short story - He broke his passenger side short shaft driving down the road one day. got it warrantied, this was about 3 months ago. Hasn't wheeled it since then, he went to go on a drive the other morning and the tire was sitting at a very rough angle, and realized his shaft was broken again.

It keeps breaking at the spindle nut, yes he preloads the bearing.

I really don't see any reason for it to break again, anybody have any ideas.

this is what it looked like the first time it happened
http://www.supermotors.net/getfile/689803/fullsize/img_2838.jpg

Does it have a cotter pin? To prevent overtorquing? As you are driving it down the road?

Yes, cotter pin with the castle nut.

so it broke twice?

Have you called SOLID and talked to them about it?
I take it this front axle has locking hubs correct? or is it a Rubicon style front D44?

Yes, it broke twice.
This is his jeep not mine - sorry if I wasn't clear enough on that part.
It's the Rubicon style. auto locking hub, just like from factory.

Yes, it broke twice.
It's the Rubicon style. auto locking hub, just like from factory.

The factory doesn't have an auto locking hub...

The factory doesn't have an auto locking hub...

i realize that. whatever youd like to call the hubs on a jeep. they arent manuals, so they would have to be auto, in a sense.

whatever youd like to call the hubs on a jeep.

Full time on a TJ...