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Originally Posted by felix_fetche
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Do you mean tempered? Are you sure it wasn't case-hardened? That would seem to be the best process for treating axle shafts, right? A nice, hard candy shell will a tough nougat center. Also, what model year was that gearbox from again? How many miles were on it? What material did you use for the cap, and what is the hardness rating of the material?
I'll revisit the gearbox from the 2006 i2 that I have open. A quick "file test" will tell if there is any hardening to the shaft at all. The new axle design (implemented some time in 2007) may have solved both of those problems. I haven't been into the gearboxes of my newer machines ('08 and '10), so I don't know if the updated axle design included any sort of axle treatment. I've got the lathe on which I could do the work, but I'd rather not if it will simply be a fools errand. Did the axle mod/repair make the machine quiet again?