Half shaft repair revisited.

[Avalon]

Interesting observation— at least to me.

I purchased 2 new half shafts and replaced the old ones especially needing the short one which sheared off at the differential.

I noticed as they were sitting side by side that there were 2 different diameters.

I measured them -
The short, sheared one is 1.24 inches(31.5 mm) at the thickest part which then tapered to each end at the spline.
The new short shaft measures 1.07 inches (27.3 mm) consistent along the whole length to the splined ends.
The long half shafts were both the 1.07 inch diameters.

Obviously, the thicker half shaft didn't prevent it from breaking.

John

[Genocache]

Likely a cost cutting manufacturing technique, Were they Britpart? They make everything smaller.

[biloxi]

The fully floating Series 1 half shafts are 31.5 mm. Due to their scarcity at the time
(about 20 odd years ago) I replaced them with 31.5mm Serie 2a half shafts with spacers,
(S2 shafts are longer) which came off a 63 ex military 109. That's all I can tell you.
.W

[GlenAnderson]

Thicker does not necessarily translate to stronger. Without knowing the metallurgy of each type, comparisons are purely speculative.

[biloxi]

They all usually snap at the splines, regardless of thickness
.W.