Hello,

On the 2003 E-150, the trans-axle has axle tubes connected to it, and at the end of each tube is installed a roller bearing. The bearing does not have an inner race, so the bearings run directly on the axle.
I had the axle go out on the passenger side, and when I pulled it, the bearings had eaten into the axle, allowing it to rise up, and thus break the seal on the bottom of the outer oil seal, so the oil started running out.

I bought a new axle kit that came with the axle, bearing and seal, and installed them. The bearing seem a little tight to me, but since it came with the axle, I figured it was OK. As soon as I drove it on the freeway, the axle hub plate got too hot to touch. I did have a leak on the front seal of the trans-axle, but had only lost about 4 oz. of oil, and the driver side hub was cool, so I am pretty sure the oil wasn't the problem.

I would sure like to know if anyone can shed any light on what the problem might be. I can get a new axle and try again, but don't want this to just happen again.

 

The first thing i would do is take it back apart. If the bearing was really the source of the heat it would surely have turned the area where the bearing runs blue from the heat. that will tell you if it was too tight.