Rear Axle Help

[askeyey]

Just had my state inspection and the mechanic found that my rear axle shafts pull in and out about an inch or so on either side. I don't think it was like this after I put my Aussie Locker in. The C-clips still hold the axles in but the extra play has me concerned.

What do you think?

 

[BGarcia88FJ62]

Jack the truck up and check for yourself 1" of play sounds kinda crazy to me.
.

 

[GLTHFJ60]

I agree, an inch sounds like a lot. Put it up on the lift and see for yourself before being concerned.

You haven't had any bad noises lately, have you?

 

[Trapper50cal]

I'm relatively certain that the Aussie install is the culprit...Did you replace any bearings in the process? Side bearings? Carrier bearings? I had a lot of slop (end play) because the Aussie was installed on the outer limits of the tolerences listed for cam gear gap. When I re-installed it as tight as I could...(barely able to install c-clips) the end play went away. also could be that bearings weren't completely seated (or races) and they finally sat themselves. Just go in and install that aussie as tight as you can and the end play will go away.

 

[Mark W]

Off the top of my head I do not believe that your axle could possible move in and out that much
there is no room in the diff for that much movement. And if they did move that much the C-clips would fall out and the axleshaft would come loose.

Bearings (either wheel or carrier) will not affect axle movement in and out of the diff. Well... catastrophically failed carrier bearings would... but you would hear the diff devouring itself and the ring and pinion gears if this were the case. And it would not be drivable beyond a short distance.

Even if the caps that secure the c clips on the axles were completely left out of the locker, you would not have room for this much movement. and the rig would probably have only made it a hundred yards after install before an axleshaft walked out.

Unless there is something I am overlooking right now I have to call BS. Check it yourself.


There were a (very?)few Aussies shipped with incorrect retention caps a couple of years back. If you got one of those and installed it without realizing the problem.... It *might* be possible to have a lot of play without actually loosing your C-clips... they would be getting damage as the axle shifted and still not room for an inch per side of play... I am not even sure that the C-clips would re retained if you did have these incorrect caps installed... but it might be possible. And I am pretty sure an inch of endplay would be causing complete failure of your axles seals too.


Check the amount of endplay yourself. this does not sound right to me.


Mark...

 

[Trapper50cal]

It may FEEL like an inch and actually be more like a half. Like I said, a loosely installed Aussie will give this much endplay and still pass its operational tests. and if a bearing wasn't completely seated when installed it would create more slop after properly seating. (assuming an inproperly installed bearing led to an improperly installed Aussie.)

 

[askeyey]

Thanks for the hints so far. When the truck was on the lift he called me in to the shop to feel for my self. there was DEFINITELY a lot of in and out movement of the axles. When I originally installed the Aussie the tolerances are all well within spec. Not on the tight end but very far from loose. The locker still operates correctly and I don't hear any new noises or feel anything different.

I'm thinking I may have one of the lockers that came with the incorrect caps (ala Mark w's comment). I bought it used with low miles. Maybe that's why it was sold in the first place.

Either way...no I don't know what to do next. I'm headed over to the shop now to check it out on the lift. I really don't want to crack open the pumpkin if I don't have to.

 

[Mark W]

How exactly would an incorrectly seated real axle bearing cause this?

The axle slides through the bearing... it does not seat on the bearing. The axle floats freely in the wheel bearing in terms of endplay

IF you did manage to fail to seat a semi floating rear axle wheel bearing, there would be no forces to cause the bearing to shift inward after it was installed.

The only way the rear axle bearing could have any impact on fitment would be if it was left hanging so far out that the axle would not slide in far enough to install the C-clip. And then there would be no continued installation unlit the problem was fixed. And the axle seal would probably not install if you left the bearing that far out either.



Again... rear axle bearing does not affect endplay. Carrier bearings do not either (aside for a diff that is destroying itself and allowing shifting of the axles in the process.


Mark...

 

[Trapper50cal]

I was thinking that it (the carrier bearing)would effect the measurement of the gap between the two cam bearings of the locker...giving a smaller gap measurement that would then increase as it seated. Is that not the case?

Not a wheel bearing out by the tire.

All I know for sure is that a loosely installed Aussie (on outer edge of tolerence) equals endplay

 

[Mark W]

When you installed your locker.... if the caps had the center section cut out of them... making them into a ring basically... then you were unlucky enough to get as set that did not get discovered at the factory. If they were true "caps", with a closed center section then that is not the problem. I am the only person I know who wound up with a locker that shipped with the wrong parts.... but there certainly could have been others...

I am not sure that the rings would retain the C-clip at all. I will see if I still have the incorrect parts here at the shop somewhere and try to take a look and see if they would let the diff function at all or if the shift would drop the clips out.


Mark...



Mark...

 

[Mark W]

A poorly seated carrier bearing... once it shifted... would let the entire diff shift in all directions... (it is tapered...)

So your ring and pinion would be chewing themselves up. Probably tearing up the locker too from the loading it is not meant to see. The excesive end play would be the result of the carrier shifting

Lots of bad sounds and damage going on and a short term problem as things failed quickly.


Mark...

 

[Mark W]

BTW.... the guys at Aussie Locker were great once they were aware of the problem. It came up in a discussion here on mud and they contacted me and insisted on shipping me the correct caps. I as just going to install it in a front diff where the rings that it had in the box instead of caps would work just fine.


Mark...

 

[askeyey]

When you installed your locker.... if the caps had the center section cut out of them... making them into a ring basically... then you were unlucky enough to get as set that did not get discovered at the factory. If they were true "caps", with a closed center section then that is not the problem. I am the only person I know who wound up with a locker that shipped with the wrong parts.... but there certainly could have been others...

I am not sure that the rings would retain the C-clip at all. I will see if I still have the incorrect parts here at the shop somewhere and try to take a look and see if they would let the diff function at all or if the shift would drop the clips out.


Mark...



Mark...

This is sounding unfortunately familiar. I'll have to see if I took pictures of all the parts. but I do believe my end caps were rings and did not have a closed senter section.

So they sent you the correct part...you reinstalled and all was good. Or did you notice it was wrong before the install. NOw that I'm thinking more nad more I just can't remember if they were rings or not. Crap.

AndI just got home from the shop. The free play is less than an inch but it is still VERY noticable.

 

[askeyey]

Lots of bad sounds and damage going on and a short term problem as things failed quickly.


Mark...

No bad sounds that I can notice and the locker still passes the wheel spin and lock test with the axle elevated. While doing that test I don't hear anything unusual. Just the locker clicking.

 

[askeyey]

Well I just check out the manufacture install instructions and they show the spacers looking like rings, but the LC install show here https://forum.ih8mud.com/80-series-tech/118690-aussie-locker-install.html shows a full cap. I think because when I went to the shop and only had the printed manufacturer install instructions I thought everything was fine since I looked just like the picture. I guess I need to track down the correct spacers and crack open the diff.

Good news is that everything is always faster the second time. Bad news is that the Amsoil is brand new. can I slavage it somehow or is that a bad idea?

 

[Mark W]

One of my customers ordered the unit I got that was wrong. it has been a couple eo yeras and I do not remember if he might have tried to install it before I saw it or if I saw it in the box. either way it was caught before it was used.



Mark...

 

[askeyey]

Bump for additional thoughts before I track down new spacers/end caps.

what do you think?

 

[Mark W]

I would pull the diff cover off and take a look before you make any assumptions.

And yes, you can reuse your new gear lube.


Mark...

 

[Gwynley]

Having just installed a lokka, the only massive play I think could happen is if the c clips are not there.

Trying to think outside the box a bit - are your U bolts ok? and any other parts of your suspension?

 

[cruiser88]

Are the seals leaking?