2000 Ford E-150 Van Axle Problem
 

I have a 2000 Ford E150 Van I use for work. It's your typical work van with shelves, racks, etc. I noticed it leaking gear oil last week and noticed oil all over the brake shoes. I drained the differential, had to hammer the axle in to remove the "c" clip and pulled the axle shaft and bearing/seal out. The axle shaft looked fine to me though I guess the section where the bearing rides on was polished compared to the rest. It was completely smooth though and truly didn't see anything wrong with it so I put the new bearing in and seal before sliding the axle shaft back in. Again, I had to whack the crap out of it to push it far enough in the differential to put the "c" clip back in. Also, the spider gears fell out, but I was able to put them back in along with the bolt that goes in the middle of the differential and pinion bolt was replaced. Reset the cover with new felpro gasket and put 2 quarts of gear oil (I know I need more).

After cleaning the crap out of the brakes by using an entire can of Brakleen, I reset the drum and wheel. I took it for a test drive and could feel grinding. I parked and saw smoke coming from the wheel, jacked it up and there was play in the axle.

This leads me to believe the axle should be replaced as well along with the bearings and seal again I feel...does anyone have any experience with this that can provide some expert insight? I can do most things myself by following directions haha I guess I'm what you call a "YouTube" mechanic. I'm a plumber by day and having this van down is costing me money. I'm currently using my personal pickup truck until this is resolved. Any help would be GREATLY appreciated! Thank YOU!