Originally Posted by Hard_oNe
It would be great to hear how you put on the pinion gear. Did you torque it without the ring gear? If so, what did you use to tighten it down? ...to crush the sleeve.
Thanks....my project is waiting until I figure this part out.
It was torqued without the ring gear since you have to set the bearing preload of the pinion only. Basically how much torque to make it spin by itself.
This isn't the most ideal way to tighten it down, and I'll probably get flamed for it but I could only get it to keep tightening with my air impact gun. I physically could not get it to budge after a certain point and didn't have many resources to apply more leverage on my socket wrench. So I held the yoke still with a 24" pipe wrench and drew a line on the side of my socket to watch it move. I'd tighten it 1/16-1/8" at a time and measure preload with the in-lb torque wrench I bought. It took awhile even with the impact gun.
Here's the update from the last couple of weeks..
I went through the diff and took it for a drive after refilling the gear oil. Noise was still there so I started by checking the u joints on the rear driveshaft to rule things out. I found that the one u joint i hadn't replaced had a damaged spot on one of the needle bearing surfaces
So i replaced it and when i was strapping down my yoke I noticed something. The first picture is the way it should look
The ear for the u joint is worn down. At this point I was thinking that this was making the clicking noises/growling. Took it for a ride and.. noise was still there.
At this point I thought I was hearing the noise more towards the passenger rear wheel. I figured at 25 bucks for the bearing and 8 for the seal I might as well replace it and see if it quiets up. Below are pictures followed by a video of how loose the bearing was on the race and noise while turning. Hopefully the videos work correctly
Threw the axle back in after the new seal and bearing install and the. noise. was. still. there.
: I think regardless if the bearing was making noise, it should have been replaced. Either way I was really hoping that was the cause.
To be honest I have no idea what the cause is and I'm severely starting to doubt my diagnostic abilities.
I'm going to replace the 10w30 in the trans with gear oil because I hear it mainly coming from the trans hump. That and the trans is the only thing that is not known to be good. I've already gone through the rear and tcase and the noise is still present so my next step is to change the fluid to see if the noise decreases and maybe narrow it to a bad bearing in the trans.
My driver side axle bearing was in similar, but slightly better shape than shown above so I haven't replaced it but I may decide to do so if the gear oil doesn't change anything. At least I can say that the rear was gone through when I go to sell it during the d44 swap. Hate to admit it but Sooner was right about having to dump more into the d35