I bought a 8.8 rear axle that came out of a 2003 Ranger that had the FX4 Level 2 package. I got a great deal on it because the whole thing basically needs to be rebuilt as it has almost 280K miles. When I popped the diff cover I saw that the pinion gear had somewhat chewed into the housing on the torsen carrier. Not much, but enough to leave marks. When I move the pinion flange there is quite a bit of play. I also noticed very small bits of metal were broken off of the tip of the top teeth on the pinion gear. However the rest of the pinion gear and the ring gear l do not see any damage.

-I'm guessing it would be a bad idea to re-use the ring and pinion if I rebuild the axle? I'm wondering if there is a lot of unseen damage from the pinion being loose and the truck being driven that way for an untold amount of miles.

-I know the torsen units are "good for life" but would it be worth it to re-use this one if it has so many miles on it? Do you guys think there is a chance that the metal fragments that broke off damaged it? I was also thinking about getting an open carrier and putting a spartan locker in instead.

Thanks in advance.

 

So , lemme get this straight...U are asking if it would be OK to reuse Broken parts for a Rebuild? I wouldn’t even think about it, but I’m sure there are Plenty of Hacks that have ....

 

Why bother, you are having this Rear Axle rebuilt, put in all new parts.

Something to think on !
Now is the time to consider if you want to put in some lower gears, are you planning taller tires, pulling more of a load, or just that seat of the pants feeling when you step on the old accelerator. Yes changing gear ratio calls for both the from the and rear gears to be changed and IT WILL cost more money than just a stock rebuild of the rear, but think ahead and save little money. Rebuild and change the rear now and the front diff later.

BUT if you do DON'T PUT THE TRUCK in 4WD with different gears in the front and rear.