Did anyone ever tell you that water is bad?
Just got home from helping out another fellow mudder with his 80. Justin hadn't planned on doing a front axle rebuild so soon, but after a recent trip to Richloam he spent a little too much time in the water. It took its toll on his truck. After a few days, his birfs stated clicking. Soon thereafter, a grinding noise showed up. I wasn't sure what to expect, but after tearing everything down we saw clear evidence of water intrusion on both sides of the axel oil seal. The grease in the hub was a mix of grease and water, and there was also water showing up in the knuckle housing.
After cleaning more stuff up, we found rust and dirt (or some kind of abrasive) in the wheel bearings. Nasty stuff - the inner wheel bearing scarred up his birf a bit but he was able to clean it up enough to make it pretty decent. A couple of the wheel bearings looked like they were bathing in rust.
We swapped birfs (I got the axel back in with the c clamp on the first try on both sides - I was pretty proud of that trick!) and put everything back together. Oh yeah, and we had to replace 10 of the 16 hub studs due to stripping or other issues (thanks for the tips Luis and Archie on that - the double-nut trick was probably the single most effective way to remove and replace them).
Justin went a title ape-s*** trying to prevent future water intrusion by using in-place gasket sealer wherever possible. I guess time will tell if it was worth the effort!
I took it for a quick spin and no more clicking, steering seemed to be perfect to me, and of course the grinding is no more now. But what a mess of a job - we were both pretty beat tonight. I think it was around a 13 hour job (26 man hrs) all said and done.
Oh yeah, and we discovered a nice transfer case leak, too. Rear main seal, just like mine I think.