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	1) Wheel loose	1) Tighten lug nuts
Rear wheel noise	2) Faulty, worn wheel bearings	2) Replace bearings
Axle shaft noise	1) Misaligned axle housing	1) Check alignment and correct
	2) Bent or sprung axle	2) Replace axle shaft
	3) Pinion bearing end play	3) Check pinion bearing preload
	4) Excessive ring gear backlash	4) Check backlash and adjust
	5) Incorrect pinion bearing adjustment	5) Adjust pinion bearings
	6) Loose companion flange nut	6) Tighten nut to specification
	7) Incorrect wheel bearing adjustment	7) Adjust wheel bearings
	8) Scuffed tooth contact surfaces	8) Adjust or replace gears
Rear axle breakage	1) Incorrect wheel bearing adjustment	1) Replace axle, adjust bearing
	2) Misaligned axle housing	2) Replace shaft and correct alignment
	3) Vehicle overloaded	3) Replace axle, reduce vehicle load
	4) Clutch grabs	4) Replace axle, repair clutch
Differential case breakage	1) Incorrect differential bearing adjustment	1) Check gears and bearings for damage, reassemble and adjust bearings
	2) Excessive ring gear clearance	2) Check gears and bearings for damage, reassemble and adjust bearings
	3) Vehicle overloaded	3) Check gears and bearings for damage, reduce vehicle load
	4) Erratic clutch operation	4) Check gears and bearings for damage, avoid erratic clutch use
Broken differential side gear	1) Excessive housing deflection	1) Replace damaged gears, check other gears for damage and check axle housing alignment
	2) Worn thrust washers	2) Replace damaged gears, check other gears for damage and replace worn thrust washers
	3) Misaligned axle housing	3) Replace damaged gears, check other gears for damage and check axle housing alignment
Differential gears scored	1) Insufficient lubricant	1) Replace scored gears and fill rear axle to capacity with correct lubricant
	2) Incorrect lubricant	2) Replace scored gears, clean housing and fill rear axle to capacity with correct lubricant
	3) One wheel spins excessively	3) Replace scored gears and service as necessary
Ring gear and pinion tooth breakage	1) Vehicle overloaded	1) Replace gears, reduce vehicle load
	2) Erratic clutch operation	2) Replace gears and avoid erratic clutch operation
	3) Ice spotted pavement	3) Replace gears
	4) Normal fatigue	4) Replace gears and examine other components for fatigue
	5) Incorrect adjustment	5) Replace gears and examine other components for wear. Make sure ring gear backlash is correct
Rear axle noise	1) Insufficient lubricant	1) Fill rear axle to capacity with correct lubricant
	2) Incorrect ring gear and pinion adjustment	2) Check tooth contact pattern
	3) Worn ring gear or pinion teeth	3) Check tooth contact pattern and replace ring gear and pinion if necessary
	4) Loose pinion bearings	4) Adjust pinion bearings
	5) Loose differential gear bearings	5) Adjust differential gear bearings
	6) Misaligned ring gear	6) Check ring gear runout
	7) Loose carrier bolts	7) Tighten to specification
Loss of lubricant	1) Lubricant level to high	1) Drain to correct level
	2) Worn axle shaft seals	2) Replace seals
	3) Cracked housing	3) Replace or repair housing
	4) Worn drive pinion seal	4) Replace seal
	5) Scored or worn companion flange	5) Replace flange and seal
Unit overheats	1) Lubricant level low	1) Fill axle to capacity with correct lubricant
	2) Incorrect lubricant	2) Drain axle and refill to capacity with correct lubricant
	3) Bearings adjusted too tight	3) Readjust bearings
	4) Insufficient ring gear to pinion clearance	4) Readjust ring gear and pinion backlash and check ring and pinion for wear or scoring