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.

 

Just curious,did you purchase the parts you replaced from Ford or someplace else?

 

Thanks for your question!

No, I purchased them online from Parts Geek. Can't afford factory parts.

I think my next option is to buy a trans-axle assembly from a junk yard.
What do you think?

 

The rear gear set is actually called a rear axle/differential..

When the axle surface is damaged like in your case, there's another option rather than a complete axle replacement. There's an 'axle saver' bearing available that replaces the stock bearing, and moves the contact or 'rolling area' to an offset away from the damage. Or, you have the option of a new/used axle. It sounds like you may not have pressed the new bearing into the axle housing bore deep enough and might have caused the new bearing to bind some.

A used rear axle is always a choice, but usually cheaper to repair the leaks as long as nothing else is failing, or the axle makes noise...

 

I know it can be difficult sometime , but I too had to learn the hard way , a lot depends on where the parts were made. Unfortunately a lot of imported junk is coming into the country from manufacturers of real garbage and sold here. Without mentioning the country of origin, I try to stick with OEM parts and most of the time the stuff is OK.
Sadly it doesn't take long before you realize some of the stuff we buy is boxed nicely , but is inferior in quality. That's why I always inquire where the parts were purchased.
If you don't mind doing the job two or three times because you think you did something wrong and it was the questionable quality of the parts , I guess it's OK.