Section 05-02G: Axle, Integral Carrier, 8.8-Inch Ring Gear
1996 F-150 and Bronco Workshop Manual
CLEANING AND INSPECTION

Inspection After Disassembly of Carrier

 
  1. Thoroughly clean all parts. Always use new solvent when cleaning bearings. Do not spin dry bearings with compressed air.

  1. Oil the bearings immediately to prevent rusting.

  1. Inspect the parts for any major damage.

  1. Clean the inside of the rear axle housing (4010) before rebuilding. When a scored or chipped gearset is replaced, the rear axle housing must be washed thoroughly. Inspection procedures for individual parts are outlined as follows.

 

Sensor, Anti-Lock Brake

Inspect the rear brake anti-lock sensor (2C190) for loose metal particles and clean if required.

 

Sensor Ring, Anti-Lock

Examine the rear anti-lock brake system (RABS) anti-lock speed sensor ring to see that it is firmly pressed onto the differential case (4204) and check it for dented, chipped or missing teeth that could result in erratic RABS performance. If damage is found, remove and replace anti-lock speed sensor ring.

 

Gears

Examine the gear teeth for scoring, excessive wear, nicks and excessive chipping. Worn, scored and damaged gears cannot be rebuilt to correct a noisy condition.

 

Bearing Cups

Check drive pinion bearing cups for deep scores, galling, or spalling. If a 0.038mm (0.0015-inch) feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its bore at any point around the cup, the cup must be reseated.

 

Companion Flange, Rear Axle

The end of the rear axle universal joint flange (4851) that contacts the bearing cone as well as the nut counterbore and seal surface must be smooth and free of nicks.

 

Cone and Roller Assemblies

When operated in the differential drive pinion bearing cups, bearing rollers must turn without roughness. Examine the roller ends for step wear. If inspection reveals either a damaged bearing cup or a damaged bearing, both parts should be replaced.

 

Carrier Housing

Make sure the differential and pinion bearing bores are smooth. Remove any nicks or burrs from the mounting surfaces of the rear axle differential carrier housing.

 

Differential Case

Make sure the hubs where the bearings mount are smooth. Carefully examine the differential case bearing shoulders, which may have been damaged when the bearings were removed. The bearings will fail if they do not seat firmly against the shoulders. Check the fit (free rotation) of the differential side gears (4236) in their counterbores.