> I decided to take pictures as I go along. See > [quoted text clipped - 14 lines] > > i YIKES! You say "unusual" damage, the drive faces of these gears should be as smooth as mirrors. Any small nicks or dings will cause considerable metal-metal contact and overheating, especially at highway speed. The hypoid gears make a VERY sliding sort of "contact", and if there are mars on the surface, that will cause rubbing of the metal. They will eventually smooth off again, I suppose. if you do try to continue using this differential, I would see about getting magnetic drain plugs for it, or making them if you have to (not very hard). Then, I would go out for a short drive, drain the diff and refill. If you want, you could take the oil and run it through a fine filter and reuse it. A large filter paper in a funnel left to drain overnight should get the metal out. The full diff contents might take several separate funnels to run through in one day, though, as that stuff is awfully thick even without foreign matter.
Otherwise, I'd keep draining and refilling it at gradually longer intervals until you don't see any metal on the magnets anymore. Of course, you HAVE to find out what bolt that retainer flap was SUPPOSED to hold in place, and re-do that section.
Oh, hell, I didn't even MENTION bearings. This kind of crud must be even harder on the bearings than the gear teeth! I think the main tapered roller bearings may SOUND fine right now, but they are going to fail for sure after this abuse.
Jon
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