I have seen them like that also.. Actually I did that to one of mine also and never had an issue, when it was in use.
It's a stress riser, I'd deburr the sharp edges and run it. There's a good chance - if - the axle broke in that spot, the wheel & tire would exit the vehicle. Something to remember if the back end starts feeling kinda loosy-goosy...
ive never seen an axle brake under the bearing. 99% of axle breakage ive seen is either right where the splines exit the side gear or where the splines stop on the axle shaft. the few breakages ive seen at the outer end are from impact like hitting a curb. the only other thing ive seen brake an axle is if the housing is really bent and the driver keeps driving, the bending of the axle will snap right at the peak of the bend.
Good to know, if i feel anything strange later on ill pull it out and inspect it and replace it then if necessary.
While this thread is still some what active, maybe someone can answer this question for me. I cannot remember what side the axles go on. Long one on the passenger side, short one on the drivers side?
Someone once told me they are both the same. I don't recall if they are or not. In my picture it almost looks like the driver side is shorter.
long should be on passenger side. if in doubt always try the long axle first. if it doesnt go in all the way then its on the wrong side.
will do, thanks. ill make sure to clean it very well afterward as to avoid any metal shavings once back inside the housing.