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07.5 - 09 3rd Gen 6.7L PowertrainDiscussion of components that are directly involved in the power production and all that is needed to get and keep the truck moving . Engine, Transmission, etc...NO ADVERTISING
Heard some noises coming from the front diff, and began to investigate. Pulled the dip stick out of my mag hytec cover and it had metal shards all over it. Drained the oil... Magnetic drain plug looked like a christmas tree. Pulled diff cover off to find drivers side spider gear all chewed up (will post pictures tomorrow). Luckily no other damage is seen. Been having a slow oil leak out that side ever since i put in new seals. Truck has been hit on the passenger side wheel before but the drivers side rim was damaged from being pushed over and hitting a curb. Now it has 28k miles. All ball joints have been replaced, Passenger axle, and both spindles. passenger seal and drivers(x2). What could have caused this? Does my axle shaft have a bend to it causing a vibration that ate the gear or do i have a bent axle housing tube. How can i check the tube? I read using a straight edge and tape measure but it didnt make much sense to me. Axle did not leak when i put it together and centered it in the tube using some wood shims. (left if for 24 hrs) However when i completed the assembly by putting the axle in the hub and setting the truck down back on its wheels i begin to see a leak. Not sure if i should buy a driver side axle shaft, spider gears, and new seal and try again and see if that fixes my problem...or did my axle tube bend from the pumpkin (all the welds are there and dont see anything that would look like it was broken) and now i will need to find someone in MI who can straighten the axle and have it trussed.
if it were me i would get a different front axle. a guy around here was selling his complete 4:10 front axle with 20k on it for 325 bucks. I picked it up for a spare.
Would you consider reselling it to me? If so PM me some info id be interested...but what im essentially trying to figure out is it seems to me from what i have read is that quite a few people on here who have been having problems with these axle tubes getting loose (breaking the welds etc)...if thats the case why get into another stock axle if i might as well truss the axle and never worry about this ever happening again. On that note is there any aftermarket front differentials that are made much stronger for this axle or any improvements that i can make if i am going to be doing some upgrades to this axle and going that route?
I would not say that the AAM 9.25 axle is weak as it is on par with the Dana 60 it replaces.
Any time an axle is hit(like in an accident) it cannot be expected to remain as true as the day it was manufactured. I think that your axle sustained damage in the accident, and that is the cause of the part failures.
Unless you can have it checked for trueness and repaired if necessary, I would not put any more money/new parts into it.
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