'02 F350 DRW Dana 80 Problems!!!!!
Ok, my '02 F350 DRW 4x4 has 112K on it now. At about 106K I had the rear R&P replaced with all new install kit (bearings, seals, etc.) b/c it had apparently had moisture in it that caused rust and deterioration of the bearings which caused the R&P to wear badly and become loud.
The limited slip clutches looked great according to the shop so they re-used the existing carrier / LS.
After a couple weeks, I started hearing a VERY odd squeak noise at very low speeds that had never been heard before they fixed the rear R&P. It was only audible with the windows down, rolling very slow and turning. I heard it a few times going straight but 99% of the time it only did it while turning... This went on for a few weeks before I could take it back to the shop. I called the shop and they advised me to add another bottle of friction modifier since they only put one in it and the D80 requires two according to Ford. This did nothing for the sound.....
To me, the sound is like a dry wheel bearing. Its VERY loud and 100% positive its from the rear axle. It sounds more like on the passenger side than the driver side when and primarily does it when turning to the right. To me this = right rear wheel bearing... This shop says the bearings are good though... I am tempted to just replace them anyway...
I started looking into other things that might be squeaking. I replaced all three rear U-joints and the driveline carrier bearing. (No change)
I brought it to the shop again a couple weeks ago. After they jacked it up, it was obvious that there was a limited slip issue. You could rotate one rear tire with the axle off the ground while in neutral and the other tire did not move. They opened it up and said the limited slip clutches still looked "ok" but that they thought they were barely touching and that was the cause of the squeak.
They also said the wheel bearings "could" be making a squeak if they get loose so they adjusted the retaining nuts to put a little more pressure on the rear wheel bearings.
Still not sure of what was making the noise, they recommended replacing the LS clutches. So, they replaced the clutches, pins and concave washers and charged me for the parts. No more noise, until today............ After a thousand miles, the noise is BACK!!!!!!!!!
ANY ideas??????????????? This is very frustrating... I still think its worth replacing the rear wheel bearings but its odd that it stopped making the noise after they worked on this last time... Maybe when they "adjusted" the rear retaining nuts, it hid the problem of bad rear wheel bearings and now they have worn more causing the noise to return??