Hello,

On the 2003 E-150, the trans-axle has axle tubes connected to it, and at the end of each tube is installed a roller bearing. The bearing does not have an inner race, so the bearings run directly on the axle.
I had the axle go out on the passenger side, and when I pulled it, the bearings had eaten into the axle, allowing it to rise up, and thus break the seal on the bottom of the outer oil seal, so the oil started running out.

I bought a new axle kit that came with the axle, bearing and seal, and installed them. The bearing seem a little tight to me, but since it came with the axle, I figured it was OK. As soon as I drove it on the freeway, the axle hub plate got too hot to touch. I did have a leak on the front seal of the trans-axle, but had only lost about 4 oz. of oil, and the driver side hub was cool, so I am pretty sure the oil wasn't the problem.

I would sure like to know if anyone can shed any light on what the problem might be. I can get a new axle and try again, but don't want this to just happen again.

 

Maybe the wrong size bearing was accidentally put in the kit.

 

You have to watch these things. If it fit it was most likely the right bearing.

When my axle got eaten up, the outer race of the bearing partially welded itself to the axle housing and left a few chunks. Make sure the axle tube is clean and smooth before installing a new bearing.

Also, the bearing that originally sold with my replacement axle was cheap and flimsy. I broke it before realizing there were chunks of the old bearing welded to the axle tube. Just thought it was a tight fit and, no, I was not wailing on the new bearing.

Once I got everything cleaned up and a new Timken bearing, everything fit back together nicely. The left over junk in the axle housing is a whole nother story.

 

Thanks chiefFX4 for your reply!

You may be right about the bearing being cheap. Got the whole kit for less than $100, and that included shipping from Parts Geek.

I haven't removed the axle yet to take a look because I still use the van for very short trips for work, but I pretty much know what I will find.

I did check the bearing seat area very closely, including even cleaning it out with Q-tips before installing the new bearing. I also got a bearing and seal setting tool from an auto parts store to be sure I didn't damage anything putting them back in.

I also pulled several rags through the tube to clean out most of the metal pieces, but they were very thin like gold leaf.

I didn't pack the bearing with grease, because I figured it was oiled with the oil put in the axle housing, but someone suggested I should have done that. What do you think? Wouldn't it just get "dissolved" into the oil as they mixed together?

Thanks again for your reply!

- Noel

 

I've never seen anywhere that says to grease the wheel bearing before installation. Like you said before, there's only once race so the grease wouldn't really stay and axles rely on an oil bath so they sit in gear oil all the time.

After my first incident, the rear end was basically wrecked. I had to take it in to have it rebuilt. I still don't think it's right. Those metal shavings are just too fine to remove and they get in every where and wreak havoc.

It cost me $750 or so to get the rebuild done. Used rear ends are going on ebay for around $500. Just have to take the time to install yourself.