When to know if axle-shafts need replaced?

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CountryBoy19

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Location
Southern Indiana
Vehicle: 2005 Yukon XL 4WD, 120k miles.



BLUF: How do I know when it's time for new axle shafts?



Details: A few weeks ago my differential carrier bearings went out. I pulled it all apart to replace the carrier bearings (and pinion bearings because metal found it's way up and started eating those too). I figured while I'm down that far I'm going to do new wheel bearings (because metal particles could have made their way out there too), new seals, and new brake dust shields...



Once I got it apart I inspected the axle shafts. Where the bearings run doesn't look badly pitted or anything but it does have a slight "sand blasted" appearance. Is that normal? There is no "rough feel" to that area, just appearance. The seals did have small grooves worn in the axles and the right seal was starting to seep. So to be on the safe side I ordered Timken repair bearings. For those that don't know, they offset the bearing track and seal tracks so they don't run in the same place.



I got it all back together and pretty significant leak on the left axle seal, almost as-if it's not really sealing much at all (diff lube slung up in the wheel well and you can smell the diff lube if you walk around that side). Ugh...



At this point I know I have to tear it apart. I was also hoping the carrier bearings would fix my rearend "clunk" but they didn't. I'm sure its the spider gears; they seemed a bit loose but I wasn't sure how loose was acceptable. I think I'm going to just take the OE G80 out and put a Truetrac in to hopefully get rid of the clunk for good. I'm considering just ditching the stupid repair bearings ($85 wasted) and going for OE bearings, seals, and new axles. Or do I even need new axles? How much wear is too much?



FWIW, I can't post pictures because it's currently back together and its the only vehicle we can fit all the kids in so I can't have it torn apart for an extended period.
 

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