Rearend Noises

Well I finally had a day off and I found the source of the noise. The cross shaft retaining bolt backed out causing the cross shaft to try to slide out and hit against the end of the pinion gear as the carrier spun around taking out the very ends of the pinion teeth and wearing into the end surface of the gear. I guess after 48 years it finally couldn't hold on any longer. This is a new one for me. The cross shaft ends are all chewed to bits. There's a nice collection of metal chunks in my drip pan and still in the housing as well. The carrier bearings are making a nice grinding/popping sound too and the pinion bearing feels pretty rough as well.

I could probably rebuild the old girl. I have a posi carrier in a CJ rearend I could rebuild with new clutches and steels maybe. It's a 4:11 gear which is way to low for this setup so I'll need a new ring and pinion too. I might could clean up the ends of the pinion teeth and get away with reusing these gears, but I don't know. The ring gear looks fine. It is a little worn I suppose, but doesn't look beat up from the metal chunks.