Clean the inside of the axle housing before rebuilding. When a scored or chipped gearset is replaced, the rear axle housing (4010) must be washed thoroughly. Inspection procedures for individual parts follow.
Section 05-02A: Axle, 10.25-Inch Ring Gear | 1996 F-250 Light Duty (Semi-Float), F-250 HD and F-350 (Full-Float) Workshop Manual |
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 axle housing before rebuilding. When a scored or chipped gearset is replaced, the rear axle housing (4010) must be washed thoroughly. Inspection procedures for individual parts follow.
Bearing Cups
Check bearing cups for deep scores, galling, or spalling. If a 0.0381mm (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
Make sure the flange half-rounds and lugs have not been damaged in removing the driveshaft (4602) or in removing the rear axle universal joint flange (4851) 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.
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.
Carrier Housing
Make sure 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 the hubs are smooth where the differential bearings (4221) mount. Carefully examine the differential case bearing shoulders, which may have been damaged when the differential bearings were removed. The differential bearings will fail if they do not seat firmly against the shoulders. Check the fit (free rotation) of the differential side gears (4236) in their counterbores. Check for cracks in differential side gear thrust washers (4228).