What
Before SR26 left for competition, I tore down the on-car 4WD assembly and the front transfer case, and helped inspect every part for cracks and deformation. A drivetrain part that fails on course ends the run, and usually the event.
How
I pulled each assembly off the car and laid the parts out in the order they came apart, so nothing went back in the wrong place. Then I cleaned each part and went over it for cracks, wear and anything bent.
The inspection found cracks in the torque limiter hubs. On the hub below, one crack runs across the face beside the bore, and a second runs from the bore into the cross hole in the boss. These hubs carry drivetrain torque, so they were not going back in.
We worked out the design changes needed to fix the problem, and I helped machine the replacement hubs. Then I rebuilt both assemblies and torqued every fastener to spec. As part of the testing prechecks I also set the front steering toe.
Outcome
Everything was back on the car before the event, and the cracked hub never saw the course.
