Just be warned it may look ok now but if it chews up the spiders like Jeff's Dak it will cost you way more at that time than now with minor problems.

It could be an axel bearing or your front end like I said before check your Hubs NOTE they can spin just great but still be tore up inside. Try this jack one side up at a time take the wheel off then spin it around a few times if you hear anything like grit in the bearing they are bad if the brakes stop this pry the calipers open some so the Hub spins easy. If bad also they may spin kind of jerky like some thing is in the bearings.

I know this sounds weird but as I said I had a Hub go bad and it sounded like it was my rear I could swear it was my rear end making that noise.

Stop and listen to people OK

 

Will do.

I know one of the RF upper A-frame bushings is toast. It's actually metal-metal on one side.

I'll check both ASAP.

Back to the Differential...

How difficult of a job is it to replace the clutch packs back there ?

 

If you had clutch packs:

You would have to pull the axles and remove the carrier first to change the clutch packs. Then there are some special tools needed, mostly to compress the springs as you install the new packs.

You can also just get a rebuilt carrier.

 

....or find a good used unit.

Would an Open carrier be interchangeable with the Traction Lock carrier ?

Does the carrier remove as a whole unit ?

I'll search around for a "How-To" article/video in the meantime.

 

Yes and Yes.

Although you will need to build/borrow/buy a tool for setting the back lash.

The adjusters have a large hex shape where the axle shaft goes through,

I was able to find a large nut that fit perfectly, and welded it onto a 4' chunk of pipe.
The tool then slides into the axle tube, and you can adjust the backlash.

(the adjusters are threaded)

Once you find a how to vid, or see the carrier pulled, you will see the adjusters I'm talking about.

They are under the retaining caps for the carrier.

 

Moses Ludell does an excellent write up on it, his books are worth having in the shop.

http://www.4wdmechanix.com/Moses-Lud...sler-Axle.html

 

Out of curiosity did you or the shop try to spin the rear wheels while the cover was off to try and see or hear anything? ALSO since you now know that the unit is NOT what should be in your truck, BY CHANCE could it be the wrong gear ratio than your front diff? say a 3.92 instead of a 3.55? The ratio will be stamped on the ring gear in plain sight with the cover off. That MIGHT be what is causing the noises? I know it would only affect things when you are in 4WD but it's worth looking into. Since the old fluid was already sucked out along with any metal or evidence of pieces parts floating around your picture does not reveal much other than the shop doesn't know what they are talking about. Who knows what else they did or didn't do the first time.

 

I did find a YT video showing those adjusters. Pretty cool idea. The dude used a flat head screw driver through the front port hole to adjust the back lash. He hit the holes as to not cause any damage. Very successful.

What does the back lash need set to ?

 

No. I told them I know Magnethead and they wouldn't allow me back there while they were tearing it down. (Lol!) They did let me back to look and take a pic though. I didn't think to ask to spin the wheel with the cover off either.

Mine is only a 4x2. Wish it was a 4x4!

I hear ya. The mechanic claimed there was no evidence of any metal pieces parts in their the last time as well. I don't think he would lie since they would've tried to sell me an expensive repair job.

I didn't even ask them how much they'd charge to rebuild it. They did offer either. I won't be going back there that's for sure.

 

BTW i have a complete undamaged 3.92 ratio differential with pinion gear up for sale IF you are interested. As stated you would have to have it adjust once installed. Each housing and carrier is different so the exact set-up numbers will vary. The video is probably one oft he best out there for setting one up.