About 2K miles ago I performed a full rebuild of the rear differential for my 93 B-150 Ram Van. It has a plain old 9.25" diff with 5-lug axles. The unit had a slow leak at the cover gasket and it eventually ran dry and scored the bearings and races something awful. My bad for not checking the gear oil often enough.

After disassembly and inspection I decided to replace the following:

Pinion Races & Bearings
Pinion Seal
Carrier Case Races & Bearings
Wheel/Axle Bearings
Wheel/Axle Bearing Seals

I re-used all of the gears, the pinion, the carrier case, adjusters, bearing caps, etc.

Tough job in the driveway, but I managed it all in an afternoon with some help from the bearing press at the local automotive machine shop. The diff was filled to the proper level with Royal Purple full synthetic gear oil, and it is still full.

The rear was almost silent (not perfect - the outer axle races had some galling) until last week when it began to groan as I made slow left and right rurns between 15 - 30 MPH on secondary roads. Anyone know what is gone wrong back there?