Looky what I found!

[Cuprum-74]

Well, today started off ok.
Until....

I was driving back to work after lunch then all of a sudden I hear this thunking noise coming from the rear end.
"Great." I'm thinking.
I pull up to the gate. "Kerchunk... Kerchunk... Kerchunk."
The security forces airman checks my CAC ID. Then says. "Hey, sarge your car is making a funny noise."
"Yeah, it just started, but don't worry I'm sure it won't blow up."
As I drive off it starts to get louder... KERCHUNK!... KERCHUNK!... *continues as I drive to my worksite*
I pull up to the parking lot sounding like hell. I decide to put it into reverse...
KERCHUNK, SQUEEEERRRKKK... CRRUUUNCH!!! *POP*

Then smooths out, no funny noise, no vibration, just all of a sudden smooth again.

I then drove 30 miles back home after work, still smooth, no strange noise. I still babied her.

Feeling paranoid I decided to start pulling off the diff cover. First thing I noticed was the cover has a dent on it, and looked like it was done from the inside.
Great, so I pull off the cover and lo' and behold the oil has metal flakes in it. I turned the wheels to inspect the carrier, ring and pinion.

And found this:

The carrier does look a little beat up, but it appears to still be pretty solid. The ring and pinion look alright as well.
This is a 8 1/4 suregrip rear with 3.21:1 gears.
I guess this might be a good time to switch to 3.55:1
What I found interesting is, I never even touched the whole thing, just changed the oil and that's it. And it somehow got loose.

 

[oldkimmer]

........u got lucky..........change the bolt and be happy.......ofcourse tork the rest of em.....kim.........

 

[ssba]

Never seen that one before.
Usually they get more busted up than this when you have those
Kerchunk sounds.
In the old days it was simplest to go to the salvage yard and buy a complete replacement
rear axle assembly and you were back on the road pretty cheap and fast.
Today since the parts arn't easy to find in the yards anymore it may be best to take the time to clean all the metal out of the housing and rebuild what you have.
If you had plans of ever swapping to a different rear such as the 8 3/4 or Dana, looks like
it may be the time.

 

[Cuprum-74]

There I edited the pictures so they fit better...
Well I pulled the diff apart. I guess the bottom portion of the bolt did break off. Approx. 1/4 inch of it is still in the carrier housing...
*sigh*:|
So that means I have to find some way to take the remaining bolt out.
That or find another carrier, I did find a possible one from a Dakota 8.25 SG. I think its an 94.
The question is, did they change the internals much in 20 years? (1974-94).

I would love to get an 8 3/4 rear end. Problem is they are hard to find and aftermarket setups are very pricey.

**EDIT**
Never mind I just answered my own question.
I GTS'ed it. (Google That Sh*t)
Yes I can use a Dakota 8 1/4 Sure Grip from 97 below. Cool!