Gears are about $200.

Given that the pinion was wandering around, the integrity of the case comes into question imo. Since you will be replacing all the internals, why not just get another entire unit, check it out, put new bearings in it and go?

Have you ever set up a rear axle before?

Even if you get it right, I would put money on that rear axle being a howler from day one. Those gears may not show the wear, but they have wear and they have a wear pattern. Once it goes back together, you may or may not match that pattern, and whatever damage is there will only get worse.

Good luck with it.

 

Overhaul kit is on order along with new carrier and spider gears. Gonna go ahead and do the u joints and axle bearings as well. I'm pretty confident things are gonna turn out well. Thanks again for the input and the well wishes!

To answer your question, no I have never put a rear end together. The guy at the drivetrain shop down the street tried to scare me into having his shop do it which of course motivated me even more! We shall see!!

 

You couldn't tell from the picture of the gears with no clutches?

 

That 3.55 rear ends sucks, that's the one that has most of the problems. irs suspension of course

 

That's my next question. A solid rear axle with coil springs is considered independent rear suspension? Or am I not understanding something?

 

IRS started in 2003, you don't have that.

 

Gotcha. So does that mean the 3.55 that I have is not as bad as the one you refer to?

 

Wasn't me who said that, I've never had 3.55's or seen any threads about them being problematic.

 

Sorry yeah I noticed that after I responded.

Another question, the overhaul kit I ordered from Rock Auto is from USA Standard and says it works for IRS too. Does that sound right? Or did I order the wrong kit? Will it be the same even though I don't have IRS? It came up as one of the options for my specific truck on their website. Also, I didn't see any other option from the same maker for the 8.8 ring gear.

 

I posted that q just based on the pic of the fluid in the cover. The fluid either had metal or friction material.

>>>>>>>>>>>Action

 

With a little more research, I found out USA Standard considers a 2002 Expy to be IRS. I had to order the kit for an 01 for it to work and saved myself $50 too. Canceled the first order.

 

Well I do believe it was a success! The noise has been reduced by 99% I still get about 1% noise on coast down at highway speeds. Which I can definitely live with. Thanks again for all the help guys!

Got my new U-joints in and the driveshaft balanced and just took it for a test drive. Very happy with the results.

 

Against my better judgement I installed the cork gasket that came in the kit. It didn't last one day. I got a slow drip already! They are so touchy on how they are torqued. Should have used the ultra gray like I first thought.

 

I was wrong. The cork gasket was fine it was the pinion seal that had sprung a leak. Maybe because I installed it prematurely and had to remove and replace it...oops. no leaks anymore and I went ahead and replaced the cork with ultra gray as well.

 

Unfortunately a different issue has come up. I installed everything per specs, got backlash to around .010, pinion preload was about 25 in-lb but now I've started to notice a vibration that's definitely at drive shaft speed but only shows up on deceleration. Goes away immediately on acceleration. Only noticeable around 60 mph and above.

Driveline shop that balanced my driveshaft after I installed new u joints says it is most likely an issue with the pinion bearing.

All bearings and races are new as well as carrier, spider gears, center pin, etc. Only used parts left are the actual gears.

The vibration isn't horrible...I just drove the truck to Tampa and back and was pretty comfortable. It's definitely something I could live with if I had to but I really want a "like new" ride if possible out of the drivetrain.

What do you guys think? What could be the issue? Thanks!