Ok I finally got around to putting my rearend back together.I put in new pinion and carrier bearings. I set the preload to 16 in-lbs. I then went and Drove the truck around for about 30 minutes every thing seemed fine then it started making noises again. Lucky for me I was 1/2 block away from the house. So I get it back in the drive way and pull it apart. First thing, I noticed it baked the paint off the the cover. I finshed pulling it apart and really did'nt see any thing wrong at first for the noise it was making,Only the rear pion bearing had a little gauling in it. BUT both axles where blued bad at the end where the c- clips ride and and the c-clip ate into the end of one axle. Please tell what I did wrong or what could be bad,defective.....

here are some pics of the axles :

<img src="https://www.f150online.com/galleries/images/6589-9837-141620.jpg"><br>

<img src="https://www.f150online.com/galleries/images/6589-9837-141621.jpg"><br>

<img src="https://www.f150online.com/galleries/images/6589-9837-141622.jpg"><br>

Thanks Ray

 

The "blueing" on the end of the axle shaft's appear to be a material process call carburizing, which is done to harden the ends of the shaft to resist wear. Can you get better photos of the pinion cone and cup and ring gear and pinion tooth surfaces?

Can you describe the noise? On acceleration? On deacceleration? Noise all the time? Noise when turning? What type of lube did you install? The lube looks sort of yellow? I do notice debris on the fill plug magnet. Did you clean the magnet after filling with new lube?

Take a look at you're axle bearings (near the wheel ends).

 

First thing Thanks gearmanx for the help!!!!
Ok Iam using synthetic 75W140. I did clean the magnet before i put it together the last time. The nosie happened so fast and I didnt drive it far. but I think it was on deacceleration an it was like a dinging like the where parts rattling in the rear end. alot of the nosie was travling up the drive shaft. And some thing i noticed this morning when taking pic's the cage on the rear pinion bearing was distored. and the axle bearing look fine.
here are some more pix

<img src="https://www.f150online.com/galleries/images/6589-9837-141794.jpg"><br>

<img src="https://www.f150online.com/galleries/images/6589-9837-141793.jpg"><br>

<img src="https://www.f150online.com/galleries/images/6589-9837-141799.jpg"><br>

 

One more thing when I was setting preload I had to tighten pinion nut to 210 ft lbs to get the the preload 16 in-lbs does this sound right or am I doing this wrong?

Thanks Ray

 

You gotta tighten the hell out of the pinion nut to get the crush sleeve moving. I never really checked for a specific value, I always ran the nut down as far as it'd go with an impact gun and use a big pull handle and a cheater bar from there. There wasn't a lot of flop or looseness in the pinion flange when you checked your preload, was there? You did check the pinion preload with only the pinion gear in place, right, no carrier and axles?

 

No just the pinon in place I did it so i didnt go to far. So I went 5lbs at a time from a 180ft lbs

Thanks For the Help!!!!!!!!!!!!!!!!

 

Well More good news today I took the pinion to the machine shop to have the bearing replaced. And he wasn't able to get the old one off with the press. So he tried cutting it off and this is what he found the bearing had welded it self to the pinion.
<img src="https://www.f150online.com/galleries/images/6589-9837-141848.jpg"><br>

 

For what its worth,

Not real familiar with the 8.8 but I know the corporate GM 14 bolts are notorious for eating themselves if you dont get that crush sleve right. The pinnion depth is not right and they will die a quick and painful death in the form of eating the ring and pinnion. That thing must have gotten really hot to weld the pinion bearing to the pinion shaft. It has to be that either the pinion bearing wasn't seated properly or was distorted from the tightening to crush the sleave or ****ed a little bit or something along that line. How did you tighten it? Seems like something had to be on a bind.

Good luck

 

It appears you may not have had the inner bearing and / or inner pinion cup fully seated and the inner bearing cone was damaged when you were fighting to get the slack out of the new crush sleeve. I see no thermal damage anywhere, except for the inner pinion bearing? My video card is a little flawed, am I correct on no other distortion to the gearset tooth surfaces?

If no other damages to the gearset and you can get the remanants of the bearing cone off the pinion stem; I would explore the possibility of taking the pinion to a machine shop and have them put in a machine grinder and lightly grind the built-up material off of the pinion stem (using grinding fluid in a precision center grinder).

 

Yes the only place there was damage was on the rear pinion bearing.
I have already ordered a new set of gears,Ring Pinion Installation Kit & posi rebuild kit. Thanks guys for all the help!!!!!!

I am sure I will have more questions when i go to put it back together.