I have a Dana 60 semi-float non-locking axle in my '04 E350. 9.75 ring gear. Thought I had a bad axle bearing as I observed some play at the driver's side rear wheel and had a clunking on decel. Replaced the bearings and still have the same play. Before I put the diff cover back on I had my dad move the wheel and noticed the side gear inside the carrier was moving side to side. This is the gear the axle slides through. As far as I can tell there's no bearing or bushing there, so any movement must mean the bore in the side of the carrier must be worn, correct?

If that's the case, can I just swap all the parts over to a new carrier and re-install? I will replace the carrier bearings while I'm there, but I am hoping I can re-use all the gears and shims. Never done a diff before so need some guidance. Thanks in advance for your input!

 

70 views and nothing? Has no one ever seen this? Help!

 

It is possible the carrier is worn out. The surface that the side gears does wear down over time. The chucking sounds you were hearing was the axleshaft clunking against the cross pin. I have seen this before on many semi float C-clip type axles.