Now onto the passenger side. Spindle looked to be in much better shape. Basically no pitting and very minor areas of discoloration from heat. Splines on axle looked to be in pretty good condition. Cleaned with 600 grit, steel wool, then lightly greased spindle. Also cleaned ABS sensor and performed the same cleaning & greasing on the brake shield and mounting area. Greased spindle bearings with Slee tool.
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Hub grease looked just as bad though. Very black, not viscous, and it was separating in spots which made me think water found its way in from previous water crossings. Also, there should be much more.
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Once again, heavy tool marks...
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Thoroughly cleaned & pounded in new races. Installed inner bearing with oil seal. Installed on spindle. Outer bearing, claw washer, adjusting nut, lock washer, lock nut. I will also note there was no evidence of liquid gasket on this passenger hub flange, but there was also no fiber gasket present
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Here's my rudimentary axle puller tool. It's made of 1" square tubing and I didn't feel like cutting it down to a manageable size so I left it 3' long because I like making things as difficult as possible. 2 holes drilled 92.5mm center-to-center with the axle bolt hole at 46.25mm. Could've used some washers since as you can see it slightly crushed the tubing, but I didn't care enough. There are nuts on the other side of the square heads bolts. All new hardware just like on the drivers side.
Snap ring size D 2.4mm; Adjusting nut @ 62ft/lbs + locking nut @ 47ft/lbs = 12.5lb breakaway; hub flange nuts torqued to 25ft/lbs; caliper bolts torqued to 91ft/lbs
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Bedded in the new brakes and she drives like a dream now! No more pulsating, weird noises or vibrations, and best of all
no more driveline clunk!! I mean it completely eliminated the clunk when switching from P-R-N-D, accelerating from a dead stop, or shifting through the gears while driving. Will recheck breakaway in ~500mi and adjust as needed.
In about 2-3wks I will be able to clean, inspect, & compare old parts (bearings, hub flange splines, adjusting/locking nuts & associated washers, etc...). I will post my findings here. Based on the amount of metal shavings caught on the drivers side ABS sensor I will venture to say both the bearings on that side did not fair very well. I will also be installing the Slee stainless steel brake lines at that time.