Mercedes C300 Broken Rear Axle

It’s been a while since I needed to use this trick and it saved me (and the customer) about 8 hours of labor. This 2010 Mercedes C300 204 chassis vehicle broke the rear axle shaft (1/2 shaft). It sheared clean off where it comes out of the side of the differential. Vehicle was in a minor accident and somehow the axle twisted and broke. We used a miller stick welder and the largest diameter welding rod we had around. We let the rod get a good molten puddle going in the center of the broken axle stub and then pushed the electrode straight into the weld puddle stopping the arc.

We quickly unclamped the rod and shut the welder off. After allowing the rod to cool we used a slide hammer with a vice-grip attached to the pulling end (This is also a neat and useful trick / tool I made). I tightly clamped the vice grip to the end of the welding rod and with one good pull of the slide hammer the broken stub popped out still attached to the electrode. The new axle went in fine and everything worked good without removing and disassembling the differential.

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