There seems to be a slight noise from the rear when breaking. Almost sounds like a bearing grind. I pulled the axles out and noticed on the passenger side gear oil all over the break assembly and back of wheel. There was also more play on the pass side axle than driver side. I didn't see any other signs of damage inside the pumpkin. The othet thing I noticed was that on the pass side axle there seems to be a grove where the axles bearings ride and on the driver side the axle shaft is completely smooth. Is the pass axle shaft supposed to be grooved ? Anyone have any other ideas what noise could be? 2002 w/ 140,000 miles.

 

Both shafts should be smooth..

So, the only time you'd hear the/any noise is during braking? You can buy an 'axle saver' bearing that moves the bearingssurface outward and off of the damaged area.. If the rear diff is 'completely quiet' except for during braking would point to the brakes for me..

 

Thanks a million for the response. I'll actually try to post a picture just to verify the axle shaft, but the passenger side is groved (or notched pretty nicely) as the driver side is smooth. I checked the brakes and they are good. [/align]

 

here's a pic just to verify the axles

[IMG]local://upfiles/9245/066E5F449FA240E9820AECF44C94441D.jpg[/IMG]

[IMG]local://upfiles/9245/094A526437784F26BC49BF7D3976C9DE.jpg[/IMG]

 

That groove was 'precision machined' by the axle bearing... That axle can be reused with an axle saver bearing available at most parts vendors.. They work well, or replace the axle and bearing..

 

Axel saver bearing for sure. Make sure you replace the seals on both side while they are out. If you have the money go ahead and buy an axel, but you will spend approx $200 for the axel. If the brake shoes got to contaminated with axel grease they will eventually crumble, but if you caught it quick enough then you should be able to spray clean with brake cleaner.

 

Might as well do it right the first time. Never mind bearing savers you guys are life savers. Thanks. I'll be back when the repair is complete.

 

So I finally got the puller and the bearing out. I threw it back together and when I spun the axles by hand it still sounded and felt a little rough. I think sice it was worn so much it may have messed up the bearings, race and shim at the carrier. When I pulled the carrier I noticed some wear marks on the shim. Any advice as far as new bearings, shims or could it be more?

 

Thought you made mention of onlythe noise when the brakes were applied?

But,,by you grabbing the axle flange/s and rotating the axle by hand, you'll most likely be turning the side gears/spiders as well as turning the carrier over..
I may have a bit more of a 'not so smooth' feel.. If your differential was 'quiet' before as far as any growl, whine/whirring, or rumble, than I'm not sure I'd suspect any other critical wear than that failing bearing/axle..If you've had/have the carrier out, and the driveshaft is/was removed check the pinion for any unuasual rotational feel or play.. If the side bearing 'races' look good, chances are the bearings are too.. Check them both as well.. If you only have movement 'tracks' on the shims/races it wouldn't concern me as long as they weren't spinning from a damaged case/caps ect..A grooved axle shouldn't put any undo strain of the side bearings.. But, 140K might Take some pics with your camera and post them if your in doubt....

 

I'll get some pics tomorrow. There was abosutely no noticeable noise until brakes were applied thats why I was so set with just the outer axle bearing repair. There are some markings on the shim between the bearing race on the carrier and the axle housing. The driveshaft and pinion were never removed and they still feel smooth and tight. I'll be back with pics. THANKS AGAIN