I have a 04 1500 with the 9.25 rear end, about a month ago it started clicking in the rear end, I took it apart and found that the drivers side axle bearing had went bad. I replaced it, now on my way home tonight, it started the same noise again! The install seemed pretty straight forward, is it possible I put the bearing in to far? I put it against the race like all other bearings usually are

 

The bearing rides on the axle surface. If the bearing was gone, the axle surface should have been marked and pitted as well. If you installed a new bearing with a worn axle, then new bearing will now be damaged. Unless you installed a new bearing repair it, which is a bearing that rides on a "new" axle surface.

 

That's the thing, the old bearing had spun in place and wore through the outter collar, I scuffed the old surface, and inspected the shaft and it didn't look very worn (enough to make a difference anyway) I'm totally baffled by it

 

How many miles are on the truck and what type of "abuse" have you put it through? (Towing, off roading, etc...)

 

It's got 105,000 on it, as for abuse I can't really say, I picked it up 11,000 miles ago. I haven't done much with it other than drive it normally. It is pushing 35's though. I haven't had a chance to take it apart yet though