Golf/GTI VI :: Frame Notch Went Smooth / Axle Is Dangerously Close To Turbo Outlet


Mar 16, 2014

Frame notch went smooth, we pulled the bag and disconnected the axle from the hub and just pulled everything out of the way. When we reassembled everything, the wheel now pokes 3/4-1 inch more than it did before. We pulled the axle back out and realigned it and made sure it seated properly and messed with the strut and its bolt to make sure there was no play or anything (it was reinstalled with the same orientation), but nothing seemed to change it. Could just disconnecting those two things cause the camber to go out of whack that badly? When installing the bags I didn't run into this issue and the camber was barely even off when I got it aligned. Trying to find out what could possibly cause it to get that far off. When I installed the bags the camber and toe barely even changed.

Also, I can't even air out all the way now because the wheels were a perfect fit before, and now they poke too much... but with 17 psi in the right front bag, the axle is dangerously close to the turbo outlet. Seems to feel like barely a business card could fit between the two. The frame notch was done correctly and was the 5th one my buddy has done.

1912298_10201505446825691_1396899283_n by Chadillac910, on Flickr

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I have 1999 F350 7.3 Crew Cab 4WD. I took it on a 4 hours trip towing a trailer to haul a small tractor on it. after 3 hours of driving, I started hearing grinding and metal chewing sound coming from the front axle or close the wheel hubs. It was awful, terrible, ... you name it!!! I had to continue or I will lose the tractor I paid for already. The sound was coming for 1-2 seconds each 500 feet or so. It never stopped or changed. I pulled over to see what's going on and found the following:

1. Left shock is leaking badly
2. Right locking hub is gone (not sure if the truck had one before). I bought this truck last year, but I never had to use 4x4 and I know the 4x4 motor by the transfer case is missing and the nipple on the transfer case is set to the 2wd position so the front drive-shaft does not turn.

I took the front shock off and continued to drive without it, the noise did not go away.

I pulled over again and this time I noticed that the dust cover on each end of the front axle is missing too. I have never worked on these axles before, but I jacked one side, and sure enough, gear oil was leaking from the other side. I took the plug off the front differential and stuck my finger in it. I felt a creamy brown-greenish stuff in the differential. The consistency is like mayonnaise or thin peanut butter. I put the plug back on and went to pick up the tractor because I did not want to miss it fooling around with the truck on the highway.

The truck made it there and back (almost 5 hours total after the break down). The sound never stopped every 500 to 1000 ft.

After getting home safely, I took the other locking hub off, and took it for a test drive. I did not hear the noise, but now my right brakes are locking.

I took of the wheels and saw that the retaining snap ring (C clip) for the front axle on the right side came off by hand. I took the washers behind it off. Took the calipers and brackets off. I have never done front axle rebuild. I am not sure what has been damaged and what's still good.

Right of the bat, I know, at least, I need 2 shocks, one brake caliper and pads.

My questions are:
1. Is it possible to take the front axles off on both sides and make it 2wd for now until I have the money to rebuild the axle?
2. Could I use the same hubs? or they are most likely damaged and how to tell?
3. How to tell if the differential is damaged/needs rebuilding?
4. How to tell if the axles/spindles are damaged?
5. Is there a step by step tutorial to rebuild the axle with all seals, bearings, ...etc? How hard is the job for a hobbyist? I do most of my repairs myself, and I was lucky at 36 years old, I never had to rebuild a differential.
6. What else I might have damaged in the process of driving it that long with the noise? How do I tell if I did?

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[URL] .....

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According to my mechanic that would be the result of changing the fluid.

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