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Hey i need some help guys. I have a 1990 f250 with a sterling 10.25 rear axle full float. I was draining the gear oil and was sweeping my finger in the little catch hole at the bottom in the inside of the housing. I pulled out what looked liked a roller bearing. But looking at bearings, they all looked fine and were larger than the one i pulled out. I then saw the top of the spider gear pin was shered off along with a hole. Do u think thats were the pin came from? And what would cause this kind of damage?
Can you get more pics of the carrier, from what I can see it looks like the pinion was having some fun with the carrier, common for the early (pretty 1993) axles to get loose pinions.
In your pic of the pin, just above it on the carrier looms like marks evenly spaced from each other that look like the pinion mite of hit it, I had a 8.8 that did that but didn't blow a chunk of the pins out but did break the bolt holding the pin in, made for a hell of a time to get out.
I took a look at the ring gear, no damage . as little as i can see of the pinion it seems to be alright in terms of damage. I know it needs to be fixed sooner vs later but do think it would still be drivable for a bit until i get a trutrac?
Check to see if the pinion is loose, if it is you can remove the nut, apply some loctite and tighten it back down to 160-180 ft-lbs and run it like that as a quick fix, to do it right you should replace the bearings and gears if they show wear or damage. As for the broken pin, you take a risk running it like that, it may stay in or it may fall out which will stop you instantly and destroy the diff.
If I were in your shoes, I'd find another diff that's 93 or new and swap that in and save all the hassle and expense of changing gears (unless you were thinking ratio change) and if funding allowed get the Detroit locker and stick it in the new axle then put it under the truck, your going to spend at least 500 on bearings and gears just to fix this axle and you pick up a jy unit for 200 or less.