Inspection

NOTE:
^ It is critical to carefully and thoroughly inspect all drive unit parts before reassembly.
^ Thorough inspection of the drive parts for wear or stress and subsequent replacement of worn parts will eliminate costly drive component repair after reassembly.

AXLE HOUSING

Inspect
- The axle housing bore for nicks or burrs that could prevent the outer diameter of the pinion seal from sealing. Remove any burrs that are found.
- The bearing cup bores for nicks or burrs. Remove any burrs that are found.
- The housing for cracks. Replace the housing if any cracks are found.
- The housing for foreign material such as metal chips, dirt, or rust.

DIFFERENTIAL

Inspect
- Pinion gear shaft for unusual wear.
- Pinion gear and side gear teeth for wear, cracks, scoring, and spelling.
- Thrust washers for wear.
- The fit of the side gears in the differential case.
- The fit of the side gears on the axle shafts.
- Differential case for cracks and scoring.
- All parts for wear and replace if necessary.

RING AND PINION GEARS
Ring and pinion gears are matched sets and both are replaced any time a replacement of either is necessary.

Inspect
- Ring and pinion gear teeth for cracking, chipping, scoring, or excessive wear.
- Pinion gear splines for wear.
- Pinion flange splines for wear.
- The fit of the pinion gear splines on the pinion flange.
- The sealing surface of the pinion flange for nicks, burrs, or rough tool marks that could cause damage to the seal's inside diameter and result in an oil leak.
- All worn or broken parts and replace if necessary.

Important: A new pinion flange must also be replaced when ring and pinion gears are replaced to maintain proper system balance.

BEARINGS

Inspect
- Bearings for smooth rotation after oiling them.
- Bearing rollers for wear.
- Bearing cups for wear, cracks, brinelling, and scoring.

Important:
^ When replacing worn or cracked bearings and cups, make sure to replace them in sets.
^ Ring and pinion gears for wear and replace them as a set if worn.
^ Low mileage bearings may have very small scratches and pits on the rollers and the bearing cups from the initial preload. Do not replace a bearing for this reason.

SHIMS

Inspect
- Shims for cracks and chips. Damaged shims should be replaced with an equal size service shim.