Drive Axle Trouble Shooting

NOTE: This is a general trouble shooting guide. When using this guide, locate the condition in column one that corresponds to your problem and determine the possible causes in column two. Match the number of the possible cause with the same number in column three, and you will have the suggested correction.

CONDITION	POSSIBLE CAUSE	CORRECTION
Rear wheel noise	Wheel loose Faulty, worn wheel bearings	Tighten lug nuts Replace bearings
Axle shaft noise	Misaligned axle housing Bent or sprung axle Pinion bearing end play Excessive ring gear backlash Incorrect pinion bearing adjustment Loose companion flange nut Incorrect wheel bearing adjustment Scuffed tooth contact surfaces	Check alignment and correct Replace axle shaft Check pinion bearing preload Check backlash and adjust Adjust pinion bearings Tighten nut to specification Adjust wheel bearings Adjust or replace gears
Rear axle breakage	Incorrect wheel bearing adjustment Misaligned axle housing Vehicle overloaded Clutch grabs	Replace axle, adjust bearing Replace shaft and correct alignment Replace axle, reduce vehicle load Replace axle, repair clutch
Differential case breakage	Incorrect differential bearing adjustment Excessive ring gear clearance Vehicle overloaded Erratic clutch operation	Check gears and bearings for damage, reassemble and adjust bearings Check gears and bearings for damage, reassemble and adjust bearings Check gears and bearings for damage, reduce vehicle load Check gears and bearings for damage, avoid erratic clutch use
Broken differential side gear	Excessive housing deflection Worn thrust washers Misaligned axle housing	Replace damaged gears, check other gears for damage and check axle housing alignment Replace damaged gears, check other gears for damage and replace worn thrust washers Replace damaged gears, check other gears for damage and check axle housing alignment
Differential gears scored	Insufficient lubricant Incorrect lubricant One wheel spins excessively	Replace scored gears and fill rear axle to capacity with correct lubricant Replace scored gears, clean housing and fill rear axle to capacity with correct lubricant Replace scored gears and service as necessary
Ring gear and pinion tooth breakage	Vehicle overloaded Erratic clutch operation Ice spotted pavement Normal fatigue Incorrect adjustment	Replace gears, reduce vehicle load Replace gears and avoid erratic clutch operation Replace gears Replace gears and examine other components for fatigue Replace gears and examine other components for wear. Make sure ring gear backlash is correct
Rear axle noise	Insufficient lubricant Incorrect ring gear and pinion adjustment Worn ring gear or pinion teeth Loose pinion bearings Loose differential gear bearings Misaligned ring gear Loose carrier bolts	Fill rear axle to capacity with correct lubricant Check tooth contact pattern Check tooth contact pattern and replace ring gear and pinion if necessary Adjust pinion bearings Adjust differential gear bearings Check ring gear runout Tighten to specification
Loss of lubricant	Lubricant level to high Worn axle shaft seals Cracked housing Worn drive pinion seal Scored or worn companion flange	Drain to correct level Replace seals Replace or repair housing Replace seal Replace flange and seal
Unit overheats	Lubricant level low Incorrect lubricant Bearings adjusted too tight Insufficient ring gear to pinion clearance	Fill axle to capacity with correct lubricant Drain axle and refill to capacity with correct lubricant Readjust bearings Readjust ring gear and pinion backlash and check ring and pinion for wear or scoring