Rear End Post-Mortem
I had a carier bearing sieze which eventually spun the inner race on the carrier. This chewed a bunch of metal off the carier making the bearings worse and making a LOT of noise. As the carrier wore it started to shift around changing the geometry of the gears and causing them to chew themselves up really quickly. When I took the cover off in the previous attempt to diagnose the problem everything looked normal. The pinion bearing didn't seem bad, no excess play in the pinion, no noticable wobble in the axles, nothing made noise when I rotated the carier by hand. It was very non-obvious except for the horrible noise and all the metal filings on the magnet.
So, a new carrier, ring and pinion (4.10 while I was at it), install kit, and labor to have it installed and I'm back in business. <img border="0" title="" alt="[Big Grin]" src="gr_grin.gif" />

