Inspection After Disassembly

Inspection After Disassembly of the Axle

Thoroughly clean all parts. The pinion seal is a synthetic rubber and must not be cleaned, soaked or washed in cleaning solvents. Always use clean solvent when cleaning bearings. Oil the bearings immediately after cleaning, to prevent rusting. Inspect the parts for wear or damage. If rust is present, remove with a wire brush mounted on a power drill or equivalent. Rinse clean with metal-prep solvent on sponge or rag to remove all particles. With a clean sponge, coat tube interior with Dupont 3012-5 Red Oxide Preparakote or equivalent. Allow to dry for a minimum of one hour.

When a scored ring gear and pinion is replaced, the axle housing should be washed thoroughly. Inspect individual parts as outlined below.

Gears

Examine the teeth of ring gear and pinion for scoring or excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring is the result of excessive shock loading, vehicle loading, or the use of an incorrect lubricant all of which contribute to the loss of lubricating film between the two gears. Scored gears cannot be reused. Examine the teeth and thrust surfaces of the differential gears. Wear on the hub of the differential side gear can cause a chucking noise known as chuckle when the vehicle is driven at low speeds. Wear of splines, thrust surfaces, or thrust washers, can contribute to excessive driveline backlash.

Bearing Cups and Cone and Roller Assemblies

Check bearing cups for rings, scores, galling, or excessive wear. Pinion bearing cups must be solidly seated in the housing bores. Check for seating by attempting to insert a 0.04mm (0.0015-inch) feeler gauge between these cups and the bottoms of their bores.

When operated in the bearing cups, cone and roller assemblies must turn without roughness. Examine the large roller ends for wear. If the original blend radius has worn to a sharp edge, the bearing should be replaced.

If inspection reveals either a worn bearing cup or a worn cone and roller, both parts should be replaced to avoid damage.

Rear Brake Anti-Lock Sensor

Inspect the rear brake anti-lock sensor for loose metal particles, and clean if required. Note any indication of rear axle assembly lubricant leakage through core of rear brake anti-lock sensor or around perimeter. Replace as required.

Anti-Lock Speed Sensor Ring

Examine the anti-lock speed sensor ring to see that it is firmly pressed on to the differential case and check it for damaged (dented, chipped or missing) teeth that could result in erratic RABS performance. If damage is found, remove and replace anti-lock speed sensor ring.

Universal Joint Flange, Rear Axle

Be sure that the surfaces of the rear axle companion flange have not been damaged in removing the driveshaft or in removing the rear axle companion flange from the rear axle assembly. The end of the rear axle companion flange that contacts the front differential pinion bearing inner race or slinger washer, as well as the flat surface of the pinion nut counterbore, must be smooth. Polish these surfaces if necessary. Note also the barrel of the rear axle companion flange for any damage which could permit the pinion seal to leak. Roughness aggravates backlash noises and causes wear of the rear axle companion flange and pinion nut, with a resultant loss in pinion bearing preload.

Differential Housing

Make sure that the differential bearing bores are smooth (if applicable). Remove any nicks or burrs from the mounting surfaces of the differential 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 bearings will fail if they do not seat firmly against the shoulders. Check the fit (free rotation) of the differential side gears in their counterbores.

NOTE: Care should be taken to prevent damage to the anti-lock speed sensor ring while handling and servicing the differential case.