UPDATE: growling noise heard coming from driveline when I let off gas/coast

[resq302]

Well,  I just had a chance to pull the axles and the third member yesterday.  Wasn't a pretty sight.   Very dark shiny gear oil came out when I pulled the third member.  When I pulled the right axle out, I noticed a primer dark gray color on the hub side of the bearings.  Keep in mind I rebuilt the rear last year and installed Green bearings which are sealed.  After I got the axle totally out, I noticed that the right side had play in the bearing.  After removing and checking the driverside, I knew the right side needed to be replaced as the left side had minimal play.  It gets worse....  after I got the third member out, I noticed the teeth were quite shiny.  None of the teeth looked to be broken or chipped from what I could see on the ring or pinion.  However, when I was cleaning up the bottom part of the axle banjo, using a magnet I picked up a lot of large slivers / chunks of metal.  I called up the local trans shop that rebuilds differentials and brought it to him and they inspected it.  They agreed that my right bearing was on its way out and I should replace it while it was out.  I was already one step ahead of him and had them on the way.  As for the differential, he looked at it and immediately said there was not enough play in it.  He said there should be about .10 thousands of play where mine hardly had any.  So that explains the growling noise as he said the rear was set up too tight.  He actually said they see a lot of them set up this way and come in with the same problem.  Rebuilders who do not do diffs that often usually think setting it up a little tigher is better as it will "break in".  Not the case.  The only think that was breaking in my differentials was the gears. 

After all was said and done, they said to come back when I have my parts and they would be happy to help me out with setting it up.  $400 in parts + $300 (guestimated) for labor = A HUGE HOLE IN MY WALLET! 

If I had let it go like some people have said I should and run it till it blows, I would have probaby would have had to replace the axles, bearings, axle housing, and basically everything.  As bad as it sounds, $700 now seems to be a lot better than spending over a thousand later on when I certainly wont have the money.

[resq302]

Here are some pics of the chunks / flakes of metal I picked up with a magnet.

[RECHRGD]

You stated earlier that you talked to the guy that "rebuilt your third member".  Doesn't he guarantee his work?  Sounds like the gear situation is his problem.  He should replace the gears for free IMO.   Bob

[resq302]

Bob, he said that it was probably the posi-unit (sure grip) unit self destructing.  If he just installed that last year and swapped it over from a 742 case, I can't see why it would go bad.  Someone correct me if I am wrong, but the sure grip units just "don't go bad by themselves".  I understand that the clutches on the 742 style sure grip wear but I can't see them causing all that metal chunks and stuff.