Rear Axle Shaft SNAFU

1984 Ford Bronco XLT

9" Rear Differential

Pulled rear axles so I could replace the third member gasket. Figured I'd go ahead and replace the wheel bearings etc while I was at it. I noticed some gouging in the axle housing, and I added some new gouges when removing the bearings. Will these issues cause a leak or am I good to go? New axle shafts and housings or could they be repaired for a reasonable price? JB weld and emery cloth to fill the axle shaft gouges? Repair bearings?

Thanks in advance for the help, information, ideas.

Yo CK,

Looks too deep from here,malt hough my tablets resolution isn't very good.

So, based on what I can see, I agree with Ford, 9" shaft oil seals are susceptible to the same kinds of damage as rear axle drive pinion seals... The axle shaft must be clean and the lip handled carefully to avoid cutting or tearing it. Axle shaft journal surface must be free of nicks, gouges and rough surface texture...

See these pics where the author wrote, "Once the axle shaft has been completely removed, inspect the bearing and seal surface. I recommend replacing the bearings for any rebuild, but if they are in good condition, you may get away with re-using them. But it’s a risk. This axle shaft uses the large ball bearing arrangement. This sealed-style bearing cannot be re-greased. You can see the wear mark from the seal. If yours has a groove, replace the shaft..."

@

http://diyford.com/disassemble-ford-9-inch-axles-brake-drum-axle-shafts/

Thanks for the info. Axle shafts will cost me more than a complete used rear end. Considering using mid priced bearings and seeing if it will hold any leaks. It's a $150 gamble though...

Funny how these small routine jobs escalate...

Yo,

I hear you on the costs and how projects grow. I did not see exactly where those gouges were. If not in seal or along bearings, it could be salvaged.

How about taking them to local machine shop?

On the axles there are gouges underneath the bearing, but not past the bearing positions. That's my main concern.

The gouging in the axle housing is a concern but not a major concern as there were no leaks before I pulled the axles.

I'm gonna take them to an axle shop for new bearings and see what they say I guess.

Hey CK,

The gouges in the axle shafts are from a cutoff wheel used to remove the bearing keeper and race.( You know that already...no worries.) They are of no concern unless you were to use the axles to their maximum torque.  I would install new seals and bearings without any worries. As you said they weren't leaking when you removed them.