Have a Dana 60 that is making a gear wine, from 40 mph to 60 mph, only under load. As soon as you lift off the accelerator, no noise. I think that it is the gears themselves but am curious if anyone has had the same experience?
Thanks, I did check the pinion yoke and u joints earlier this year. And saw nothing obvious. I will pull the cover and check the backlash and pattern this winter.
The backlash generally doesn't cause a whine. Just a clunk. With the cover off, you can measure both. Just keep in mind that if the pinion is not deep enough, that will also increase backlash, so if the backlash is out, don't stop measuring. It is probably out because of the pinion gear.