1. Home
  2. Ford Trucks
  3. Rear Axle Issues

Rear Axle Issues

I have a 2003 E-150 Clubwagon w/ Towing Package and 5.4. The rear axle is an 8.8" 3.55 w TracLoc. Van only has 28k miles. For the record, the only things I've ever towed were a car once (300 miles), and a 5x9 utility trailer w/ furniture a couple times. The car was a load, but the utility trailer was very light.

About 6 or 8 months ago, which would be 4-6k miles, the dealer replaced the clutch packs in the axle due to shuddering on acceleration. That fixed the suddering, but it had a growl audible at low speeds. The dealer asked me to let it break in for a couple hundred miles before I complained. Well, I just let things go a little longer than that, because I have plenty of warranty.

I've been planning to take it back for the axle noise anyway, but this week when I got my tires replaced, the tire guy pointed out that the pinion seal is now leaking. I really dread axle issues.

I have an appointment tomorrow, but I want to have a little working info when I take it in. What do you guys thing of all this? The axle hasn't been exactly right ever since they worked on it the first time. What could cause the growling? Is that the same thing that's messed up the pinion seal? May I assume that at this point the pinion bearing is prematurely worn, damaging the seal?

I have the Ford top-of-the-line 6/60 extended warranty, but I really plan to keep the van longer than that. I don't want this axle issue to be a recurring problem. Could I demand a replacement axle? Considering they didn't know how to fix the thing the first time, I'm not terribly confident that they'll fix it well this time.

What do you think?

CJB

Reply to
CJB
Loading thread data ...

Rear axles are generally pretty dependable and the Ford 8.8 has no design flaws. You are supoposed to change the lub in them from time to time though and if you do not you can have problems later on like what you are seeing. That rear axle has to work kinda hard hauling your van around so it is important to service it regulalry. Your growling noise tegether with leaking pinion seals tends to suggest bad pinion bearings. Do not let the deal blow you of on this one. Get ring & pinion replaced with bearings (because when bearing wear they through mesh off and change wear pattern and gears will likel never be quiet again) Also if you plan to tow more more, now would be a good time to twist their arm it install a different ratio while it is apart for repairs.

----------------- The SnoMan

formatting link

Reply to
SnoMan

The dealer f*cked it up. They had to remove the carrier to replace the clutch packs and in the process screwed up the ring& pinion gear mesh. The dealer is feeding you a load of bull...the R&P is *already* broken in, you weren't replacing those. The carrier should have been re-installed exactly as it was before it was taken out, if not it's probably set up wrong and it will seriously screw things up, including the R&P, carrier bearings and pinion bearings, which is why you now have a leaking pinion seal. The growling you hear is the ring and pinion destroying themselves.

Take it in and don't let the chimpanzee who did the original work touch it. Have someone with experience working on axles do it. Setting up an R&P is not difficult but it's an exacting process that is easy to screw up, so I take mine to an axle shop.

Reply to
Matt Macchiarolo

As of this posting, I see two responses. Both of you are in apparent agreement that the ring and pinion gotta go. Do you really think I'll talk them into a ratio change? If so, I'd think a 3.73 would be sufficient, wouldn't you?

Thanks again,

CJB

Reply to
CJB

Better than a 3.73 and it will not hurt MPG with OD tranny. Honestly a

3.55 is a bit tall anyway with a OD tranny.

----------------- The SnoMan

formatting link

Reply to
SnoMan

I agree that the 3.55 is overkill with the O/D. In the mountains the thing won't even hold it's empty self at speed without gearing down.

Now, what do you think the odds are of me getting the stealer to swap it that way for me?

CJB

Reply to
CJB

Pretty good because they owe you for the incomveinacne caused by the screw up of their repair. Check and se what ratis were option in that truck when it was built. ALso it a 4.10 is a option, it would do a LOT better on hills in OD.

----------------- The SnoMan

formatting link

Reply to
SnoMan

And the great thing about Ford axles is when you regear you won't have to reprogram the speedometer...it takes the speed signal right off the carrier so it doesn't care what ratio you have.

Reply to
Matt Macchiarolo

I did not know that. Excellent.

At this point, the dealer still has the van. They had some miscommunication between the service writers and the techs, so I went in on Friday afternoon to demonstrate my concerns directly to the shop foreman or head tech or whatever his title is. He's a very nice guy.

Fortunately, he not only listened to the noise, but he also listened to my concerns over the leaky pinion seal and probable bearing, pinion, and ring gear damage.

I'll hear back from them sometime today, and we'll see how it goes.

Thanks again,

CJB

Reply to
CJB

MotorsForum website is not affiliated with any of the manufacturers or service providers discussed here. All logos and trade names are the property of their respective owners.