I've got a 97 Dakota 4X4 that I had the 8.25" rear end kind of implode on itself recently. The spider gears are SHOT, broken retainer clips, pieces of the clutch pack rings and other assorted carnage inside the housing when I removed the cover. So I pulled everything out and apart, the carrier bearings as well as the pinion bearing look to be OK; NO pitting or discoloration. I've located a replacement complete Track Lok carrier assembly with ring and pinion (same 3.92), bearings, retainers and adjusters from a low mileage truck. So my question is: Can I keep my original pinion gear installed that is already set-up for the axle housing and then take the original ring gear off my BAD carrier, put it on the good replacement carrier, and install and adjust it? OR would it be better just to put in BOTH the replacement ring & pinion and new carrier and have it all adjusted? I've been told that if you remove and reinstall the same pinion in the same housing it came out of you don't have to put a new crush sleeve on or have it re-adjusted. Any advice or recommendations would be appreciated.

 

No problem re-using the ring gear (as long as it stays with it's mated pinion), but it's always recommended to install a new crush sleeve whenever you have the pinion out.

 

That's what I figured. Now to find one...NONE of the parts places in the whole STATE; NAPA, etc. have one in stock %$$@?! You've got to be kidding me.......

 

consider what state you are in. Probably costs too much to keep much stock up there.

 

While I have you, would it be a good idea to press on new bearings even if the ones on there now look to be in good shape? Also the ONE bearing in the nose of the diff housing along with the pinion seal, should I pop new ones in there as well? I take it you can drive that bearing out/ in without a press? Nothing was leaking or making noise before the implosion....
And one last question just so I know: There are NO SHIMS in this rear end? Just the crush sleeve and the carrier adjusters, right?

 

Would it be easier, and faster, to just swap out the rear axle with a good one? You can use a 9 1/4" as well.

 

I was considering that option...Maybe IF I could find one that's NOT $600-800. And then the whole rear axle would have to be checked out for serviceability instead of just the carrier, which might lead to replacement of brakes and other things. Where I KNOW everything else on my current axle is good. I've only got $325 in the complete carrier now and trying to keep costs down to a minimum.

 

There's no benefit to replacing good bearings. If there's nothing wrong with them, save your money. And you are correct, your rear axle uses no shims on the differential side bearings, only the pinion. Makes the job 100 times easier (as long as you have the special adjuster tool).

 

I believe that is true to some extent but in my case, with all the metal pieces parts I pulled out of the housing there had to be some of the smaller bits floating around and getting into the bearings. So I would feel much better with all new ones. And I've heard that the pinion bearings are a weak point on the 8.25's. I've got a Timken rebuild kit from Amazon on the way...