Section 05-02D: Axle, Rear, Dana
1996 F-Super Duty Workshop Manual
CLEANING AND INSPECTION

Inspection After Disassembly

  1.  CAUTION: The bearing assemblies will fail if they do not seat firmly against the shoulders.

    Thoroughly clean all parts. Always use new solvent when cleaning bearings. Do not spin dry bearings with compressed air.

  1. Oil the bearings immediately to prevent rusting.

  1. Inspect the parts for any major damage.

  1. Clean the inside of the differential case (4204) before rebuilding.

  1. When a scored or chipped ring gear and pinion is replaced, the axle housing 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 pinion bearing cup and the bottom of its bore at any point around the pinion bearing cup, the pinion bearing cup must be re-seated.

 

Cone and Roller Assemblies

When operated in the bearing 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, both parts should be replaced.

 

Pinion Flange (End Yoke)

Be sure that the flange lugs have not been damaged in removing the driveshaft (4602) or in removing the pinion seal from the pinion. The end of the flange that contacts the bearing cone as well as the nut counterbore and surface of pinion seal must be smooth and free of nicks.

 

Gears

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

 

Brake Sensor Ring, Anti-Lock

Examine teeth of speed sensor ring. Replace if any are broken or missing.

 

Carrier Housing

Make sure that the differential and differential 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 bearing shoulders of differential case, which may have been damaged when the bearings were removed.

Check the fit (free rotation) of the differential side gears (4236) in their counterbores.