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What brand?

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Maybe some type of vibration? Harmonics can do funny things

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All 4 u joint bolts have been hitting something? ,The issue maybe the axle wrap up and putting drive shaft in a bind would be my best guess

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GOOD eye... I didnt see that, but you are right....
unless that happened after the shaft and yoke hit the
ground... the reason I say that the one nut looks
way more ground off.... but good eye
Question for the OP.... you dont have those big caps
that hold the U-joint in do you... they will hit the
drive shaft when the shaft turns(instead of the bolts)

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All 4 u joint bolts have been hitting something? ,The issue maybe the axle wrap up and putting drive shaft in a bind would be my best guess

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All 4 u joint bolts have been hitting something? ,The issue maybe the axle wrap up and putting drive shaft in a bind would be my best guess

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That could be from when it hit the ground spinning at 100+ mph?

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Is that break right where the splines start? Maybe not enough radius on the edges where the splines begin? That would make it break really easily right there.

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No vibration very smooth going down the track

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what if the pinion nut was not torqued to spec? could that cause this?

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All 4 u joint bolts have been hitting something? ,The issue maybe the axle wrap up and putting drive shaft in a bind would be my best guess

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That could be from when it hit the ground spinning at 100+ mph?

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We have seen this quite a few times and have done it once myself.Usually it's overtorque that caused the problem.I assumed my airwrench would only torque to 150# wrong.I was left holding the yoke in my hand.Many assume the torque setting for a pinion nut is 240+# or as tight as you can get it with a 2 foot cheater pipe.There are varied setting depending on the pinion stem diameter and if it's straight or tapered.These specs can range from 125#ft to 250#ft.Always check with the manufacture for the correct setting.My thoughts are use a new lock nut,locktight and tighten as needed,you can even center punch the nut in several places to insure it doesn't back off.

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What case was this ? 741 , 742 or 489 ? If a 489 did you use a solid spacer or the crush sleeve ?

Did you have a pinion snubber ?

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489 case, solid spacer, and no snubber SS springs Just got off the phone with Richmond and because i got the gears from a friend and the receipt is gone, they will not help me...

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We have seen this quite a few times and have done it once myself.Usually it's overtorque that caused the problem.I assumed my airwrench would only torque to 150# wrong.I was left holding the yoke in my hand.Many assume the torque setting for a pinion nut is 240+# or as tight as you can get it with a 2 foot cheater pipe.There are varied setting depending on the pinion stem diameter and if it's straight or tapered.These specs can range from 125#ft to 250#ft.Always check with the manufacture for the correct setting.My thoughts are use a new lock nut,locktight and tighten as needed,you can even center punch the nut in several places to insure it doesn't back off.

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Pinion nut was tighten to allow for the correct preload on the pinion with new bearings it was set to 20 inch pounds of rotation drag..

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The pinion nut does not set preload.The crush washer if used or if its a straight pinion shims are used to set preload.

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We have seen this quite a few times and have done it once myself.Usually it's overtorque that caused the problem.I assumed my airwrench would only torque to 150# wrong.I was left holding the yoke in my hand.Many assume the torque setting for a pinion nut is 240+# or as tight as you can get it with a 2 foot cheater pipe.There are varied setting depending on the pinion stem diameter and if it's straight or tapered.These specs can range from 125#ft to 250#ft.Always check with the manufacture for the correct setting.My thoughts are use a new lock nut,locktight and tighten as needed,you can even center punch the nut in several places to insure it doesn't back off.

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Pinion nut was tighten to allow for the correct preload on the pinion with new bearings it was set to 20 inch pounds of rotation drag..

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The pinion nut does not set preload.The crush washer if used or if its a straight pinion shims are used to set preload.

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My correction on the set up I used the spacer with shims to set preload