- Not serving wheel bearing ever 30K miles.
- Not setting breakaway preload properly during wheel bearing service. Leaving wheel bearing loose, causing chatter (vibration) of wheel bearing. Evidence of chatter can be seen on scoring/grooving of claw washer (as seen in below pic)
- Not setting hub flange snap ring gap to spec of less than 0.20MM.
- Not lubing axle brass bushings & needle bearings when doing a wheel bearing surface. Brass Bushing wears increasing snap ring gap.
The above condition or just wide gap, along with reusing old snap ring. Is when we see snap ring just pop off.
What happens is wheel bearing chatter from being loose. This chatter causes scoring in claw washer, which loosens bearing more increasing chatter. Axle moves in and out of hub flange due to excessive snap ring gap, more than the .19mm maximum allowed. As axle moves in and out the vibration turns hub flange and axle into a saw. Sawing away at teeth of each other. The axle is a harder metal so hub flange gets the worst of it.
Improper service Leeds to claw washer scoring
You can also see how this snap ring and cone washer took a pounding. This snap ring was near just popping off.
Cone washers are designed to give a little, taking up shock. But this one is scored from improper wheel bearing serves.
I replace hub flange and cone washer often. I always recommend when replacing front drive shaft eliminated to the number one cause of D-N-R clunk.. Properly serviced wheel bearing help protect the front drive shaft, which are pricey!