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 This broken leaf spring normally...  This broken leaf spring normally wouldn’t be a big deal, but because it is the main leaf and the pack doesn&8217t have military-wrap eyes, the axle was located only by the other leaf spring. Fortunately, the fabricated traction bar helped to hold the axle in place. A chain was wrapped and bolted to hold the spring together; it held for the rest of the weekend and the drive home. Always keep a short length of chain and bolts in the toolbox. They can be used to repair springs and hold steering boxes to the frame, or as a clamp to hold engine or trans mounts together. |
 As luck would have it, this...  As luck would have it, this Land Cruiser engine mount broke after we had used our chain for another repair. Two hose clamps were put together to make one long enough to wrap around the mount and brackets. This fix actually held for several weeks. Take extra hose clamps along on trail rides; you&8217ll be surprised at what you can fix with them. |
 We&8217ve said it before,...  We&8217ve said it before, but if you have never popped a bead, you have too much air in your tires. Reseating can be done with just about any air source; we’ve even used a handpump before. In most cases only the outer bead will pop off, so holding the tire in this fashion and airing up will usually seat it. If it&8217s stubborn, a ratchet strap can be used to collapse the center of the tread, which spreads the beads apart. Pouring some type of liquid on the bead and wheel will help create a good seal. Be sure to clean any debris from the inside of the tire and on the bead-and-wheel surface. |
 Driveshaft separation like...  Driveshaft separation like this can be avoided if you make sure everything is in good working order before hitting the trail. To fix it, sometimes the vehicle can be jacked up--letting the suspension droop--and then the shaft can be reinserted into the yoke. Otherwise, one end of the shaft will need to be unbolted so the two pieces can be reunited. When slipping the shaft together, it is important to phase it properly. Some driveshafts have markings that identify the proper phasing. |
 We thought that the hub had...  We thought that the hub had broken, but once it was removed, the axleshaft was found to be the culprit. It had literally exploded inside the spindle. |
 Since we were a long way from...  Since we were a long way from home, care was taken to remove all foreign material from the hub-and-bearing area. If we&8217d had a replacement axle, we could have changed out the broken shaft. A magnet would work well, but all we had was a screwdriver to fish out the metal pieces. |
 The hub body and cap were...  The hub body and cap were reinstalled to keep dirt out of the wheel bearings. Driving with the other hub unlocked and the transfer case in two-wheel drive kept the broken shaft from damaging any other components. This vehicle had lockers front and rear, so if the going got tough the other hub could be locked and then driven in three-wheel drive. |
 If you have long-travel suspension...  If you have long-travel suspension and no room for a 60-inch Hi-Lift jack, chaining the suspension to the frame before jacking up the vehicle to change a tire can make things a little easier. |
 This Wrangler knuckle and...  This Wrangler knuckle and U-joint have seen better days. The broken joint allowed the shafts to pass each other, popping both ball joints. |
 The frontend had been converted...  The frontend had been converted to a locking-hub design, so the caliper, wheel bearings, rotor, and spindle needed to be removed to pull out the broken axleshaft. |
 Once the shaft is removed,...  Once the shaft is removed, a rag is stuffed in the axletube to keep out debris. To get the ball joints back in position, a bottle jack was placed under the lower joint and raised until the balls slipped back into their sockets. The sockets of the joints were then bent inward around the ball to keep it together. The spindle and brakes are reinstalled in the opposite order of removal. |
 Early Broncos are known for...  Early Broncos are known for bending tie rods. This one had been bent, then straightened and reinforced with a triangulated piece of strip steel and a gusset. An onboard welder is necessary for trail repairs like this. |
 Having an onboard welder can...  Having an onboard welder can make trail repairs less of a hassle. Tack-welding U-joint caps into wobbled-out axleshafts, repairing cracked frames, and welding gussets to bent tie rods are all possibilities with a mobile welder. |
 The owner of this Nissan knew...  The owner of this Nissan knew his vehicle&8217s weakness and came prepared with four complete sets of tie rods. He also had all the tools to change them, including this pickle fork to remove ball joints. |
 To make sure the alignment...  To make sure the alignment is correct, the threads behind the jam nut are counted on the bent end. The new end is adjusted to the same spot and threaded into the tie rod. |
 Once installed and properly...  Once installed and properly adjusted, the end can be bolted back to the knuckle. If your spare tie-rod ends have grease fittings, be sure to prelube them or bring a grease gun along. |
Trail breakage isn't anything new. In fact, for some of us it's a popular pastime. It can make a trailride a nightmare if you don't prepare for it. It can also turn your 4x4 adventure into a learning experience. We've been on some pretty good trails and have encountered and encouraged some cool damage, on other vehicles and our own.
The key to surviving trail casualties is to be prepared. If you know the weaknesses of your vehicle, then carry those parts. For example, if you have broken U-joints before, you'll more than likely do it again. And don't forget to bring the tools needed to perform your trail surgery. Not only will you impress those around you, but you may be able to help someone who is not as prepared as yourself.
Every group seems to have one or two members who always break something. These are the guys to watch: They’ll know what broke even before they get out of the drivers’ seat. Spare axleshafts, hubs, U-joints, and all the tools under the sun can probably be found in their vehicles. If you don’t have much experience with breakage fun, then you might want to talk to some of these guys. See if you can help them out or at least watch when they repair their broken vehicle. Here’s a look at some of the trail repairs we’ve spotted.