Removal of broken through axle

OT_SEREH · May 8, 2020

Hello,

I`ve got a broken through axle on a Marzocchi 55 RC3 (2009). Broken means, the lever (picture 2) turns freely without turning / unthreading the axle itself. Also the allen screw on the lever turns freely without (dis-)engaging.

Now I know, there is a way to get the axle / front wheel out anyway, because my mechanic (who sadly no longer exists) did so years ago (without any power tools

). But I don`t know how he did it.

How I think the axle looks:

The Lever

Other side

Has anyone any ideas how i get the thing out?

customfab · May 12, 2020

Is the axle still under tension or is it just the handle that's broken off? If it's broken in half it should be relatively easy to loosen it from the threaded end.

Aglo · May 12, 2020

I'm only guessing, but if you remove the handle maybe you can use a hex key or a socket wrench to remove the thru axle.

OT_SEREH · May 13, 2020

customfab said:
Is the axle still under tension or is it just the handle that's broken off? If it's broken in half it should be relatively easy to loosen it from the threaded end.

The axle is still under tension. Only the handle ist loose / does not grip.

OT_SEREH · May 13, 2020

Aglo said:
I'm only guessing, but if you remove the handle maybe you can use a hex key or a socket wrench to remove the thru axle.

I was guessing that too, the thing is I cannot remove the handle - the allen screw on top of it (that you see in the picture) just spins loosely

OT_SEREH · May 13, 2020

Any more ideas? Otherwise I`m "stuck" here - hoho

slomtbr · May 13, 2020

Wedge a screwdriver between the lever and the fork and pry while turning the allen screw. Maybe it will bite and you can remove it.

Lone Rager · May 13, 2020

What's that hook like thing do that's sticking out of the end of the axle? Does it move up/down in/out or something? Might it affect whether the lever engages the axle?

OT_SEREH · May 31, 2020

slomtbr said:
Wedge a screwdriver between the lever and the fork and pry while turning the allen screw. Maybe it will bite and you can remove it.

Already tried that but no success...

OT_SEREH · May 31, 2020

Lone Rager said:
What's that hook like thing do that's sticking out of the end of the axle? Does it move up/down in/out or something? Might it affect whether the lever engages the axle?

That is some kind of a safety hook - you have to push it inward, so you can open the axle. Otherwise the axle ist stopped from turning out by the hook. So it is just some kind of hook on a spring.

OT_SEREH · May 31, 2020

Any more ideas?

My mechanic at the time was able to remove the front wheel with the lever spinning freely as it is now. So there must be a way...

Aglo · May 31, 2020

On the disc side, the interior of the thru axle is keyed or is just round?
Did you try to unwind the axle with the wheel on the horizontal, not vertically as we normally unwind the thru axles. I say this because you probably have something broke that is not engaging and maybe using the gravity you can somehow make that happen. Try shaking it with either DS an NDS up.

Lone Rager · May 31, 2020

Can you pull the lever outward and possibly engage the axle...maybe while holding that hook in?

Removal of broken through axle

OT_SEREH

Attachments

customfab

Aglo

OT_SEREH

OT_SEREH

OT_SEREH

slomtbr

Lone Rager

OT_SEREH

OT_SEREH

OT_SEREH

Aglo

Lone Rager

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