BEWARE: EMPI aftermarket bus CV T-1 Axle stubs part #16-2304

[aircooledtechguy]

We interrupt this forum for a timely warning about a potentially faulty product which may be on your car right now. . .

Anyone using EMPI stub axles part #16-2304 may want to consider removing them from their cars. As with most shinny EMPI parts, these are made in China with no regard for quality. This is the result of their use on a Baja with absolutely NO OFF ROAD USE since their installation:





It should be noted that no one was hurt in the failure above, however new axle stubs, brake parts (and underpants ) were required to be changed. A quality stub axle should NEVER break just cruising down the freeway. . . EVER!! You've been warned.

Now back to your regular forum posting. . .

[CopperBaja]

Wow!

Did you damage anything else...or just the stub axle and the trash can lid?

[aircooledtechguy]

It's not my car. The damage was limited to the brake backing plate (smashed flat and ground down a bit) and some very minor body damage to the fender and body from the tire departing. The guy was VERY, VERY lucky that he didn't crash since he was @ freeway speeds when his wheel passed him

[Tom Notch]

Crap parts.


And I'd advise him to change to press-in studs at the same time.

[kyle_pc_75]

That is unacceptable. Engine tin that doesn't fit well....make it fit. An engine that blows up in 5000 miles...you took your chances. But parts that compromise our safety...that's just scary. Reminds me of Fight Club.



JACK (V.O.)
I'm a recall coordinator. My job is
to apply the formula. It's a story
problem.

TECHNICIAN #1
Here's where the infant went through
the windshield. Three points.

JACK (V.O.)
A new car built by my company leaves
somewhere traveling at 60 miles per
hour. The rear differential locks up.

TECHNICIAN #2
The teenager's braces around the
backseat ashtray would make a good
"anti-smoking" ad.

JACK (V.O.)
The car crashes and burns with
everyone trapped inside. Now: do we
initiate a recall?

TECHNICIAN #1
The father must've been huge. See
how the fat burnt into the driver's
seat with his polyester shirt? Very
"modern art."

JACK (V.O.)
Take the number of vehicles in the
field, (A), and multiply it by the
probable rate of failure, (B), then
multiply the result by the average
out-of-court settlement, (C). A
times B times C equals X...

CUT TO:

INT. AIRPLANE CABIN - MOVING DOWN RUNWAY

Jack is speaking to the BUSINESSWOMAN next to him.

JACK
If X is less than the cost of a
recall, we don't do one.

BUSISNESS WOMAN
Are there a lot of these kinds of
accidents?

JACK
Oh, you wouldn't believe.

BUSINESS WOMAN
... Which... car company do you work
for?

JACK
A major one.


Ugh.

Kyle

[baja5]

It's a shame that all we seem to have left is Chinese crap to buy. And even when there is a quality part available to buy, Most VW folks are just too cheap to step up. I know that I have said this before and will surely take crap again, but when all you want to pay for is cheap parts, you get CHEAP parts. I'm glad on one was hurt.

[Lotrat]

An old VW guy once told me, "Keep as much "VW" in your VW as you can." The more I work mine, the more I understand what he meant.

[Chris V]

Many an old VW mechanic have said it, "I hate this 'hi performance' crap"...

Last I heard the owner of this ride switched to welded conversion stubs and will be picking up some genuine Porsche stubs for back-up.

[Tom in PA]

I've broken my share of converted vw stubs so I avoid the empis like the plague. I was quite surprised to see Race Ready carrying then. They said they've had good results but I still just called and had conversions made.

Tom

[tikotiko]

dam son

[turboblue]

I sell only the conversions.



Thing stubs work when you can find them.

[50sboy]

Well...you are correct...many of the parts are made in Taiwan & China for sure and I wish that people were willing to pay a little more to get a little more....but nothing is sold with disregard to quality.

I would like to see the axle and send for material testing. We used to make them right here in the building in Anaheim, but we still have not experienced a failure since having them made overseas.

Please just send back to my attention so I can check it all out - then I will post the results good or bad.

Call (ask for Bud) or write me for a RGA - Include your name, address, phone etc. - I'll call you when I receive it...and during the testing process....

[Lotrat]

50sBoy, I assume you work for Empi... What are the possible causes of this kind of failure that exist with a good part? The splines on the stub should fail before the axle snaps IMO. I could understand HP limits on it, but none are published. A manufacture could also blame "off-road abuse". I don't think either are the issue here. So what do you hope to find in your testing? A NPF is unlikely, so it's logical for the casual observer to assume that it's just a cheap low quality part. I'm not sure if there is much interest in hearing about Empi looking at a failed part. The market would love to hear how Empi is going to improve quality. The market is ready to pay more. Must of us have learned our lessons with the cheap stuff. The "perceived" and "actual" level of quality may be different, but the Empi brand needs work. I would rather use a 40 year old part from a junk yard than a new Empi part in most situations. I'm not trying to rag on you, just trying to paint an accurate picture for you. Just my 2 cents other opinions may vary. Thanks for posting here.

[fusername]

what he said. I have had better luck with original 30+ year old CV boots than EMPI replacements. I take old and used over new on anything thats not a set of points and condser

[Ol'fogasaurus]

If you look at the cross-section of the break (great picture by-the-way), you will notice that it looks like there was a flaw in the material about half way across one side (the smooth material sometimes looking like shale rock) and the other have broke when the flawed side gave way (looking like broken material i.e.., bumpy material that has been torn apart). Not being an expert; I would guess that the flaw was either in the basic material (mix/manufacture including the moving/forming of the metal) or in the heat treatment. I have seen breaks like this before on axles usually when they have been over heated by bearing failure, failure due to age, or by poor manufacturing processes. Not good!

One would think that it should be EMPI's job to have a detailed process specification written, followed by, and proper testing done (in the manufacturing contract) to ensure that the parts are indeed being made to the spec.

Lee