Mk7 Rear Diff Rebuild Guide

[northernboy]

2008, Single rear wheels Long Wheelbase 2.4 6 Speed Panel van 95K miles

I have a suspect bearing noise from the rear axle. I have changed both wheel bearing whilst changing disks so have eliminated them as a possible cause.

The oil level is correct

I suspect the Diff or prop shaft but there is no obvious play on prop shaft.

Mild rumble start about 3oMPH and get louder up 60 then levels off. Not much difference in noise on acellerate or decelerate.

As the noise is more a rumble that a wine I suspect it is the Diff Bearings rather than crown and pinion ??

I don't really want to just buy a second hand axle as that diff may also be worn out.

I see bearing kits are available but cant find any guide on how to rebuild the diff .

I have a good collection of tools and feel I could rebuild a diff with right guide

Anyone provide a guide on how to rebuild together with torque, backlash settings etc?

[metalworker0]

Put this into youtube search.

rainman rays diff rebuild

You'll see several that he's done and without specialist equipment .. some are limited slip .. but you'll get the idea.

On one, you'll see, he has painted the crown wheel https://www.youtube.com/watch?v=JtNx6J8dfp4 to check the mesh .. and some use crush washers on the pinion to set this, (pinion bearing crush sleeve) https://i.ebayimg.com/images/g/CREAAOSw ... l1600.webp F150 i think - three vids i think on the f150 .. least it's a ford, not sure how different. but various techniques are shown.. never seen him use a dial indicator or spring balance weighing scales. all done with feel and eyesight.

all the best.mark

[knobby1]

2008, Single rear wheels Long Wheelbase 2.4 6 Speed Panel van 95K miles

I have a suspect bearing noise from the rear axle. I have changed both wheel bearing whilst changing disks so have eliminated them as a possible cause.

The oil level is correct

I suspect the Diff or prop shaft but there is no obvious play on prop shaft.

Mild rumble start about 3oMPH and get louder up 60 then levels off. Not much difference in noise on acellerate or decelerate.

As the noise is more a rumble that a wine I suspect it is the Diff Bearings rather than crown and pinion ??

I don't really want to just buy a second hand axle as that diff may also be worn out.

I see bearing kits are available but cant find any guide on how to rebuild the diff .

I have a good collection of tools and feel I could rebuild a diff with right guide

Anyone provide a guide on how to rebuild together with torque, backlash settings etc?

Easy things first...Have you eliminated the propshaft support bearings as the issue, they fail with monotonous regularity..?? They're known to cause grief. Diff bearings rarely fail on these Dana axles.

No change in noise when accelerating/decelerating is a bit suspicious.

Lord Knobrot

[northernboy]

Thanks for the responses - I will review the recommended guides on Youtube etc -

The bearing kit I have seen does include a crush spacer.

Will also double check the PropShaft supports but was recently given a good inspection at MOT where I saw the tester give the prop shaft a good push and pull to check the support bearings.

Thanks

Nick

[knobby1]

Thanks for the responses - I will review the recommended guides on Youtube etc -

The bearing kit I have seen does include a crush spacer.

Will also double check the PropShaft supports but was recently given a good inspection at MOT where I saw the tester give the prop shaft a good push and pull to check the support bearings.

Thanks

Nick

The propshaft bearings may not have any movement...but they may be rough running.

Lord Knobrot

[T350camper]

Knobby is probably right (as usual) and this might sound stupid, but have you ruled out tyre noise? Some makes of tyre can produce unusual noises that sound like wheel bearing rumbles. Do the tread-blocks have a sharp edge to them? Just a thought...good luck.

[metalworker0]

or flats on tyres from standing

all the best.mark

[tranmx2]

There was a variety of noise coming from the back of the 2000 DRW Luton back MWB.
After a few months the noise occured when moving forward from a stop in 1st gear.
The noise became more like a screach.
The noise came from the hanger bearings.
The 2005 Iveco DRW tipper XLWB did much the same thing it too had the hanger bearings replaced.
I think it was the back hanger bearing that I could not do myself and needed to go to a small garage who had the gear to remove the hanger from the prop shaft.
I think it was the nut which required an impact driver to get it off. I did not get the nut to move even with a samson bar on the socket.
I remember now he held the shaft in his arm whilst operating the impact driver with his other hand.

In the 70s Ford had a 7.5 ton small truck at that time that truck and other Fords needed a stretcher to open the diff case to allow the diff to be taken out and put back in.
Better to know the required tools before starting a job.

[dumper]

On my X BT mk 4 had a noise on the transmission. It turned out to be the centre bearing on the propshaft while fishing in Ireland had to drive 100 miles to get back to where we were staying it got really loud had to pour gear oil on it every 20 miles to back every time it got loud to try and find out if that’s your problem it’s possible a bit messy to find out if it’s not but maybe silicon spray will work.
As above on fully floating axles you supposed to use a spreader but it can be done without

[northernboy]

Thanks for continued suggestions

I have now replaced both prop shaft carrier bearings -but the noise continues. It could be tyres but they are standard van tyres - not too chunky etc but really thinking it can only be the diff. I am sort of getting used to it and cant face another few days under the van.

[T350camper]

On my van, I replaced the O/S/F tyre and noticed wheel bearing type noises (especially between 40 and 50mph with the window open slightly). This turned out to be the tread pattern on the tyre (Davanti). There's nothing wrong with the tyre or the bearing. Now I know what the sound is, I'm not bothered...but will buy a different brand of tyre next time.

[dumper]

If there’s no noticeable play in the pinion and wheel bearings and oil level ok I wouldn’t be to concerned or unless it’s really bad before I retired I work for one of the big 3 bus companies and some of axles the noise was really bad but the only time they were changed them was when they stopped driving