The sellers refunded me the money, as they were "out of stock". I am
out high and dry, without the wrench, will look some more.

i

I seriously doubt that adjusting the backlash is going to be anything but a
waste of time. If the rear end needs work the only logical procedure is to
disassemble it and have a good look at all of the bearings and gears. Then
either get another rear end or replace the damaged parts and adjust it
correctly.

The only possible exception would be if the non-functional lock resulted in
the loss of correct adjustment but no damage to gears or bearings. This
seems very unlikely, especially since metal particles were found. In light
of all that has been discovered and done, I believe you have damaged pinion
bearings. The carrier bearings, gears and remaining axle bearing would all
be suspect and are best examined after disassembly.

If you feel adventurous, go for a rebuild. You will certainly learn from it.
It is not difficult but requires patience, decent mechanical skills, and a
willingness to follow directions carefully. I would definitely disassemble
it, even if I decided to replace it.

Don Young

Yes, I ordered a real tool, it was not that expensive.

Because I am not sure what the issue it. It is easy enough to open the
diff and pull the axles the second time.

i

Don't do this.

No pins!  A hex fits into the hole of the adjuster.

If you suspect the carrier bearings why not just go ahead and replace them while
you have it open?

beekeep

OK guys... My plan for now is as follows.

0. The noises that I have are of two distinct kinds, a whining noise
that appears when I ease the gas pedal, and grinding noise that I hear
at low speeds.

1. I received the adjuster lock tab replacement from the dealer.

2. I will take off the diff cover again, and will try to adjust the
adjuster lock to reduce backlash to spec, using a dial indicator to
measure backlash. I hope (and would like you to confirm) that I can do
it using a screwdriver through the access hole.

3. If I cannot get a screwdriver through the hole, I could pull the
axle, and make a tool that goes through the axle hole and turns the
adjuster. I would make it out of some materials, I have a welder. What
I will need to know is dimensions of the tool (ie where to place the
pins etc).

4. After I do that, I will drive around to verify that the whining
noise is gone. If not, I will take the truck to a dealer. I realize
that the grinding noise at low speeds may remain, could be due to
trashed bearings.

5. If the whining noise is gone, I will take the diff apart and
replace the bearings that may have caused the grinding noise. I am
not, yet, sure whether it is easy or not to put it back together
correctly.

Does this plan make sense?

i