Inspection After Disassembly

Inspection

Thoroughly clean all parts. Always use new solvent when cleaning bearings. Do not spin dry bearings with compressed air. Oil the bearings immediately to prevent rusting. Inspect the parts for any major damage. Clean the inside of the housing before rebuilding. When a scored or chipped gear set is replaced, the axle housing must be washed thoroughly. Inspection procedures for individual parts are outlined as follows.

Sensor

Inspect the Rear Antilock Brake System (RABS) Sensor pole piece for loose metal particles and clean if required.

Excitor Ring

Examine the Rear Antilock Brake System (RABS) excitor ring to see that it is firmly pressed onto the differential case and check it for dented, chipped or missing teeth that could result in erratic RABS preformance. If damage is found, remove and replace excitor ring.

Gears

Examine the pinion and ring gear teeth for scoring, excessive wear, nicks and excessive chipping. Worn, scored and damaged gears cannot be rebuilt to correct a noisy condition.

Bearing Cups

Check bearing cups for deep scores, galling, or spalling. If a 0.O38mm (0.0015 inch) feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup must be reseated.

Cone and Roller Assemblies

When operated in the cups, bearing rollers must turn without roughness. Examine the roller ends for step wear. If inspection reveals either a damaged cup or a damaged cone and roller assembly, both parts should be replaced.

Companion Flange

Be sure that the flange half-rounds and lugs have not been damaged in removing the driveshaft or in removing the flange from the pinion. The end of the flange that contacts the bearing cone as well as the nut counterbore and seal surface must be smooth and free of nicks.

NOTE: Bronco and F-150 vehicles are equipped with half-round companion flanges. E-Series vehicles are equipped with a circular companion flange.

Carrier Housing

Make sure that the differential and pinion bearing bores are smooth. Remove any nicks or burrs from the mounting surfaces of the carrier housing.

Differential Case

Make sure that the hubs where the bearings mount are smooth. Carefully examine the differential case bearing shoulders, which may have been damaged when the bearings were removed. The bearing assemblies will fail if they do not seat firmly against the shoulders. Check the fit (free rotation) of the differential side gears in their counterbores.