I noticed this area inside the differential housing was ground down. I guess the carrier bearings were so worn that the bolt-side of the carrier was flexing into the housing.
That’s not so bad, but this next part is. I did more reading this morning and found an article about what to look for when you are buying a used axle. When I read the caption of this photo, the proverbial gears in my head started turning, and when I walked out to go look, my heart sank. That critical surface has in fact been ground down all to hell. Even if I did have a carrier that fit correctly, I would never be able to get the preload right.
Even the ring-side surface is all jacked up.
So now I am faced with having new material welded to the axle and re-machined, or finding a good used axle housing and using it. This is depressing.
NOTE: to see all my posts about the Dana 60 Axle, click here.