Took apart my front diff today. It has not felt right ever since breaking the
driver side axle shaft and putting in the new (used) one a few months ago. The best way I could describe it is it felt like it was binding up, almost like the lunchbox locker was sticking? It also seemed like I could feel something through the steering wheel, like a "tick" feeling. Both of these happen on sweeping turns at 45mph range speeds, and when the wheel was at full lock maneuvering in my driveway.
I've filled the gas tank twice since then, so I've gone maybe 400ish miles. Only driving in town to feel it out and keep it from sitting, but it just doesn't feel right.
I emptied the diff and the fluid looks pretty shiny, I did not expect to see this many flakes in the new fluid.
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It seemed pretty sparkly draining.
So, I took out the front diff and I guess I expected to find some "smoking gun" of a bearing race being ground up or something, but I really didn't. Trying to avoid a massive photo dump, but...
The races look nice:
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I replaced my dana 30 a few years ago with a HP 30 from an XJ for bearing issues, but it was super obvious. Squealed, the races were heavily scored, and the rollers in the bearing were chipped. I'm not exactly sure where to go or look from here, if anyone might have ideas?
I took the entire diff, lunchbox locker and all, apart, and didn't see anything, though I have a bunch of pics, but none of them seem very relevant. I do remember the locker (re-used from original dana 30) was right at the edge of the acceptable tolerance specs between cam gears in the new diff, like 0.001" away from not being usable. So maybe I should try putting it back together and seeing if that has drifted out of spec?
Also, can you check the pinion bearing without taking it apart?