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What kind of posi units are people running in their Bronco's? I have a 93 Bronco and 6 months ago replaced both front and rear diff's. The rear got a Auburn and the front received a Trac Loc. This last weekend the rear unit literally blew out. Blew chunks right through the diff cover. It only had 13,000 miles on it. I know that running 35's is hard on differentials but shouldn't they last more than 13,000 miles? This is only the second time I have had it out in the dirt and been playing hard on it.
RUN - don't walk to your nearest knowledgable alignment/differential/4x4 mechanic and have him/her check it out. Sounds like you may have a drive shaft/diffenential angle problem.
I'm unclear how a d/s angle problem (pinion angle) would cause a carrier to blow out? Anyway, I'd seriously consider a full-case locker. Something like a Detroit is about as strong as you can get. Dont' bother w/a Crap-Lok, this carrier has even less material to it than a stock open carrier. My .02
I have an auburn in the back of mine too and a tru-trac in the front. I have about 45,000 miles on it with 35's and 4.56 gears. I have had no problems. Sorry about yours, that sucks.
What do you think of the Auburn? Is it noisier or less smooth than, say, the Traction-Lok? Can you take a slow, tight turn on dry pavement without it "ratcheting"?
the Auburn is quiet, I have never had any problems with noise or ratcheting noises. It turns out that i bent my axle housing and that is what caused things to bind up. I am replacing the new rear end with a Eaton limited slip. Hopefully this will do better than the Auburn.
If you can still change your mind I'd avoid the Eaton. I can put you in touch w/a guy who destroyed one, on less than difficult terrain, if you want. Was on an '87 Bronco w/302 and 8.8. I saw what was left and it wasn't pretty.