I'd suggest taking a deep breath and holding it for while so you stop
hyperventelating. There, OK now?

Looks like the retainer lock was installed backwards, just snapped off.
This would give you the score mark on ring gear. Neither of those items
really concerns me other than ranting about nincompoops at the factory.
I would be concerned if the bearing retainer had moved. If it was loose,
you will have trashed the bearings as well as gotten abnormal wear on
the ring/pinion.

Since I doubt you have any warranty coverage, it's up to you. I'd clean
up the whole assembly so you can see what it looks like without the oil
residue. A good wear pattern is centered in the ring gear teeth. Lots
more info in lots of places, try this for starters, keep looking.
http://www.ring-pinion.com/downloads/yukoninstman.pdf

If the tooth wear looks ok, finish flushing the gear case, put in fresh
oil, keep going. Perhaps drain and flush again in 30 to 60 days.

If the wear pattern shows that it has shifted over time or there is alot
of backlash, time to call in an expert and have them rebuild it.

Shrug. What other choices do you have?

Go to alldata.com and check the TSB Titles to see if there was a recall
ot TSB that might be applicable. You have to pay to get the full
bulletin, but the titles are generally descriptive and free. If you find
one that sounds applicable you can check with the dealer for the full
detail.

Pete C.

Personally, I'd first check backlash, record it, then pull the carrier,
flush and check the carrier bearings, based on the grit you found in the
bottom of the can.
It's not difficult to reset the lash / bearing pre-load on this type of
set-up, same thing as a Ford 9" as far as that goes. Check your wear
pattern on the ring gear and pinion. While you have the carrier out,
check the pinion bearings for feel and any backlash.
See how much wiggle you have (if any) in the spiders and make sure the
pins are still corretly in place.
Pull the axles, replace both bearings.  While you have it all apart,
clean the inside of the housing really good, including the tubes. You
want to get all of that grit out of there that you can before you re-
install anything.
All that grit sloshing around is probably what got your axle bearing(s).
If one has failed, the other is not far behind, which is also why I
suspect the carrier bearings are going to be damaged, and probably the
pinion bearings also.
If the lock has broken off, the possibility that the preload was lost
early on is relatively high, which is not a good thing.
Definately check for the TSB's.
I would just replace all the bearings and seals while I had it apart
(pinion included).

I really think you're going to be a lot better off to take it to a shop
that knows what they are doing, setting up a rear isn't something you
want to learn by guessing and "trying".

BDK

Probably not, but it can't hurt to ask.

Here's how the dealer will look at it:
If you've been a _good_ customer of the local dealer, the service department
might go to bat for you with the regional rep.
If you did all the routine service yourself (or anyplace other than the
dealer), this is where you get spend all the money you saved.

Sorry, but that's how the game is played.

-Carl

Iggy,

It seems to that the lock was improperly installed. Therefore the side
adjuster backed off, causing the ring gear to develop excessive backlash
(which would cause noise when taking your foot off the gas), and the ring
gear moved over enough to break off the improperly installed lock.

I would remove the ring gear and carrier, wash out the banjo with a full can
of brake cleaner, blow out with air. Clean the ring gear, bearings, races
with brake cleaner and air. Re-install everything and previously described
and you should be good. Don't forget a new cover gasket. I prefer a gasket,
but a bead of silicone works too.

I wouldn't recommend using a power washer as someone posted, the water can
be impossible to get out of the axle tubes, and you will contaminate your
new gear oil and get milky.

You can try to get Dodge to make the repair, you have a good case, but it
might be easier to fix it yourself than deal with that hassle.

While your at it this is a good time to install a limited slip differential

Tony

Iggy,

Before you get too deep in this thing, take five minutes to do a local
search on car-part.com for another used axle in your area.  I did that
with 2.3L Ford engine
and managed to find an engine with only 30k on it for less than I'd
already spent
on diagnostics.  Before you get too far into this, take a quick check
to see if
there is a cheap replacement around, it may mean you could then rebuild
this
one (or not) at your leisure...

 --Glenn Lyford