Axle thread repair
 

Hi,
I was in the process of doing my torsen swap, when I noticed that the threads on the new rear axle I got had been messed up in the removal process. They're not completely messed up, just enough that I can't get the nut started. I was thinking I could run a die of the right size and pitch over the threads in an attempt to save the axle. Does anyone know what size and pitch the threads are on the axle? Any other ideas to save the threads?

I don't know the pitch but you might be able to take a little of the end of the shaft off with a grinder if you are careful.

Grab a thread file like this one:
https://www.miataturbo.net/attachmen...ine=1358976805

It has 8 different thread pitches on it, and costs less than a die, which only has one size. Obviously takes a little more effort to clean up a thread, but I'd rather have 8 thread pitches with unlimited diameters than have to pay for a full set of dies.

Pics of the axle and or threads.

As stated above, you could hit it with an angle grinder at about 45 degrees all the way around. If not a grinder, a file will work just as well just takes longer.

Here are some pics (from my phone, not the best)
https://www.miataturbo.net/attachmen...ine=1358985004
https://www.miataturbo.net/attachmen...ine=1358985004
Looks like the guy I got the axles from mushroomed the axle and tried to grind it down to its original shape. In the process, he hit the threads, making it impossible to start the nut.
The biggest thing is getting the nut started. The threads are only messed up at the beginning. I thought about a thread file but I decided that a die would be a better solution to help cut a new starting thread that matches up with the rest of them. If no one knows the pitch, then I guess I'll get a thread file.

You can repair a thread sometimes with a triangular file.

^This, or if not available use a small narrow file.

http://www.harborfreight.com/media/c...mage_18497.jpg

The main advantage of the thread file in your case is that the file will fall into the good threads and follow them, only taking damaged material away where needed. If you get a die it has to thread on, just like your nut (which won't start) so while it will grab and start cutting a thread it might not start exactly where needed and you can bugger up the whole thing.

They also sell dies that are hinged so you can clamp it onto the good section of thread and back it out. They're expensive though.

the axle still looks savable. much rather use the thread file, they're always handy to have around.