Axle Shaft Questions/Frustrations

[CountryBoy19]

New guy here, it seems this forum has a lot more well-versed mechanics than the SUV forums so I'm coming over here to ask.

 

Vehicle: 2005 Yukon XL 4WD, 120k miles.

 

BLUF: How do I know when it's time for new axle shafts?

 

Details: A few weeks ago my differential carrier bearings went out. I pulled it all apart to replace the carrier bearings (and pinion bearings because metal founds it's way up and started eating those too). I figured while I'm down that far I'm going to do new wheel bearings (because metal particles could have made their way out there too), new seals, and new brake dust shields...

 

Once I got it apart I inspected the axle shafts. Where the bearings run doesn't look badly pitted or anything but it does have a slight "sand blasted" appearance. Is that normal? There is no "rough feel" to that area, just appearance. The seals did have small grooves worn in the axles and the right seal was starting to seep. So to be on the safe side I ordered Timken repair bearings. For those that don't know, they offset the bearing track and seal tracks so they don't run in the same place.

 

I got it all back together and pretty significant leak on the left axle seal, almost as-if it's not really sealing much at all (diff lube slung up in the wheel well and you can smell the diff lube if you walk around that side). Ugh...

 

At this point I know I have to tear it apart. I was also hoping the carrier bearings would fix my rearend "clunk" but they didn't. I'm sure its the spider gears; they seemed a bit loose but I wasn't sure how loose was acceptable. I think I'm going to just take the OE G80 out and put a Truetrac in to hopefully get rid of the clunk for good. I'm considering just ditching the stupid repair bearings ($85 wasted) and going for OE bearings, seals, and new axles. Or do I even need new axles? How much wear is too much?

 

FWIW, I can't post pictures because it's currently back together and its the only vehicle we can fit all the kids in so I can't have it torn apart for an extended period.

[volfan84]

we replaced the gears in my brothers truck and it didn't leak or make any noise at first.  after a couple hundred miles, it started whining very loud and some diff fluid slung everywhere under there.  it ended up being the pinion nut needed to be tightened.  tightened it up and no more leak or whine.

[CountryBoy19]

17 hours ago, volfan84 said:

we replaced the gears in my brothers truck and it didn't leak or make any noise at first.  after a couple hundred miles, it started whining very loud and some diff fluid slung everywhere under there.  it ended up being the pinion nut needed to be tightened.  tightened it up and no more leak or whine.

So the pinion nut backed off or it was never tightened right to begin with?

 

I believe I've got my pinion nut tightened properly. Hammered it down with the impact until the crush-sleeve yielded a bearing preload of 14-19 in-lbs rotating torque.

 

My problem is the axle seal leaking, leaked right from the start... It seems there isn't really anybody experienced with what a good axle shaft looks like and what a worn/bad shaft looks like so I went ahead and just bought new axles. Motiv 1541H axles were less than $100 ea... hopefully I never have to touch this rear-end again. I hope to get another 200k miles out of it.