Axle gear noise can be caused by insufficient lubricant, incorrect backlash, tooth contact, worn/damaged gears or
the carrier housing not having the proper offset and squareness.

Gear noise usually happens at a specific speed range. The noise can also occur during a specific type of driving
condition. These conditions are acceleration, deceleration, coast, or constant load.

When road testing, first warm-up the axle fluid by driving the vehicle at least 5 miles and then accelerate the vehicle
to the speed range where the noise is the greatest. Shift out-of-gear and coast through the peak-noise range. If the
noise stops or changes greatly:

•

Check for insufficient lubricant.

•

Incorrect ring gear backlash.

•

Gear damage.

Differential side gears and pinions can be checked by turning the vehicle. They usually do not cause noise during
straight-ahead driving when the gears are unloaded. The side gears are loaded during vehicle turns. A worn pinion
mate shaft can also cause a snapping or a knocking noise.

BEARING NOISE

The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be
either a whining, or a growling sound.

Pinion bearings have a constant-pitch noise. This noise changes only with vehicle speed. Pinion bearing noise will
be higher pitched because it rotates at a faster rate. Drive the vehicle and load the differential. If bearing noise

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FRONT AXLE - C200FE

occurs, the rear pinion bearing is the source of the noise. If the bearing noise is heard during a coast, the front
pinion bearing is the source.

Differential bearings usually produce a low pitch noise. Differential bearing noise is similar to pinion bearing noise.
The pitch of differential bearing noise is also constant and varies only with vehicle speed.

Axle shaft bearings produce noise and vibration when worn or damaged. The noise generally changes when the
bearings are loaded. Road test the vehicle. Turn the vehicle sharply to the left and to the right. This will load the
bearings and change the noise level. Where axle bearing damage is slight, the noise is usually not noticeable at
speeds above 30 mph.

LOW SPEED KNOCK

Low speed knock is generally caused by a worn U-joint or by worn side-gear thrust washers. A worn pinion shaft
bore will also cause low speed knock.

VIBRATION

Vibration at the rear of the vehicle is usually caused by:

•

Damaged drive shaft.

•

Missing drive shaft balance weight(s).

•

Worn or out of balance wheels.

•

Loose wheel lug nuts.

•

Worn U-joints or C/V joints.

•

Loose/broken springs.

•

Damaged axle shaft bearing(s).

•

Loose pinion gear nut.

•

Excessive pinion yoke run out.

•

Bent axle shaft(s).

Check for loose or damaged front end components or engine/transmission mounts. These components can contrib-
ute to what appears to be a rear end vibration. Do not overlook engine accessories, brackets and drive belts.

DRIVELINE SNAP

A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged) can be caused by:

•

High engine idle speed.

•

Transmission shift operation.

•

Loose engine/transmission/transfer case mounts.

•

Worn U-joints or C/V joints.

•

Loose spring mounts.

•

Loose pinion gear nut and yoke.

•

Excessive ring gear backlash.

•

Excessive side gear to case clearance.

The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a
hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a
mechanics stethoscope is helpful in isolating the source of a noise.

FRONT AXLE - C200FE

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DIAGNOSTIC CHART

Condition

Possible Causes

Correction

Wheel Noise

1. Wheel loose.

1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing.

2. Replace bearing.

Axle Shaft Noise

1. Misaligned axle tube.

1. Inspect axle tube alignment.
Correct as necessary.

2. Bent or sprung axle shaft.

2. Inspect and correct as necessary.

3. End-play in pinion bearings.

3. Refer to pinion pre-load
information and correct as
necessary.

4. Excessive gear backlash
between the ring gear and pinion.

4. Check adjustment of the ring
gear and pinion backlash. Correct
as necessary.

5. Improper adjustment of pinion
gear bearings.

5. Adjust the pinion bearings
pre-load.

6. Loose pinion yoke nut.

6. Tighten the pinion yoke nut.

7. Scuffed gear tooth contact
surfaces.

7. Inspect and replace as
necessary.

Axle Shaft Broke

1. Misaligned axle tube.

1. Replace the broken shaft after
correcting tube mis-alignment.

2 Vehicle overloaded.

2. Replace broken shaft and avoid
excessive weight on vehicle.

3. Erratic clutch operation.

3. Replace broken shaft and avoid
or correct erratic clutch operation.

4. Grabbing clutch.

4. Replace broken shaft and inspect
and repair clutch as necessary.

Differential Cracked

1. Improper adjustment of the
differential bearings.

1. Replace case and inspect gears
and bearings for further damage.
Set differential bearing pre-load
properly.

2. Excessive ring gear backlash.

2. Replace case and inspect gears
and bearings for further damage.
Set ring gear backlash properly.

3. Vehicle overloaded.

3. Replace case and inspect gears
and bearings for further damage.
Avoid excessive vehicle weight.

4. Erratic clutch operation.

4. Replace case and inspect gears
and bearings for further damage.
Avoid erratic use of clutch.

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Condition

Possible Causes

Correction

Differential Gears Scored

1. Insufficient lubrication.

1. Replace scored gears. Fill
differential with the correct fluid type
and quantity.

2. Improper grade of lubricant.

2. Replace scored gears. Fill
differential with the correct fluid type
and quantity.

3. Excessive spinning of one
wheel/tire.

3. Replace scored gears. Inspect all
gears, pinion bores, and shaft for
damage. Service as necessary.

Loss Of Lubricant

1. Lubricant level too high.

1. Drain lubricant to the correct
level.

2. Worn axle shaft seals.

2. Replace seals.

3. Cracked differential housing.

3. Repair as necessary.

4. Worn pinion seal.

4. Replace seal.

5. Worn/scored yoke.

5. Replace yoke and seal.

6. Axle cover not properly sealed.

6. Remove, clean, and re-seal
cover.

Axle Overheating

1. Lubricant level low.

1. Fill differential to correct level.

2. Improper grade of lubricant.

2. Fill differential with the correct
fluid type and quantity.

3. Bearing pre-loads too high.

3. Re-adjust bearing pre-loads.

4. Insufficient ring gear backlash.

4. Re-adjust ring gear backlash.

Gear Teeth Broke

1. Overloading.

1. Replace gears. Examine other
gears and bearings for possible
damage.

2. Erratic clutch operation.

2. Replace gears and examine the
remaining parts for damage. Avoid
erratic clutch operation.

3. Ice-spotted pavement.

3. Replace gears and examine
remaining parts for damage.

4. Improper adjustments.

4. Replace gears and examine
remaining parts for damage. Ensure
ring gear backlash is correct.

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