Worn rear axles Chrysler 8.25 27 spl

[tonybeirut]

Hi guys.
I was searching for my problem but ddnt find good info.

I noticed a metal friction sound when cornering to the right so I went to the garage and they removed the axles from the diff and inspected them to find this problem.

Both my rear axles end (the end of the axles after the C-clip and not the splines) are worn around 2 inches.

I have 94 xj country. 4.56 gears. Arb lockers. 33x12.5x15 bfg tires.

They told me that the C-clip is fine. Spider gears fine. Cross pin fine. We found pieces of metal in the oil of course.

They filled the worn end with weld and I told them it's not a cure . The weld will fall and debris will kill the gears and the ARB locker.
They filled 80-90 sae oil and closed the diff.

I will buy new OEM axles and install them at another garage. We don't have 1541H or chromoly 27 spline in here.

The questions are . Is it normal for axles to wear that much? What is the cause of this problem? If I buy and ship Yukon 1541H will solve it forever?

Any help is appreciated.

[4.3LXJ]

I am not sukre what wear you are referring to. Can you post some pics of it?

[tonybeirut]

Attached is a pic. The worn part of the axle is circled in red. It's not my axle I took a pic from the net.

[Mudderoy]

I am not sukre what wear you are referring to. Can you post some pics of it?

How would the ends even touch? I'm confused.

[4.3LXJ]

I am not sure how you would get wear there either. One thing though, if they welded it the metal is softer there and will fail again. New axles is a good plan

[tonybeirut]

If the spider gears are loose or worn and start moving up and down or in and out, the axles slides beyond the spiders toward the carrier and start to touch something and wear. Maybe the cross pin?

And maybe the Spider gears were loose and those axles were worn before I changed the carrier with a ARB locker and we didn't notice the wear at that time.

That's my point of view I'm not an expert but Im trying to explain things the way I understand.

[Poorboy]

Did the axle bearings look like mine? :nuke:
http://i262.photobucket.com/albums/ii102/poorboy_616/New%20Jeep/20160213_194111_zpsqyjyc6yt.jpg (http://s262.photobucket.com/user/poorboy_616/media/New%20Jeep/20160213_194111_zpsqyjyc6yt.jpg.html)

I noticed a tiny bit of wear on the ends of the shafts in my 8.25", but not enough to become an issue. Yours... look much worse. :O

New shafts aren't horribly expensive, but I would replace that cross shaft and lock bolt along with them. They wear on each other, so replacement is warranted on all of the components.

[tonybeirut]

Did the axle bearings look like mine? :nuke:
http://i262.photobucket.com/albums/ii102/poorboy_616/New%20Jeep/20160213_194111_zpsqyjyc6yt.jpg (http://s262.photobucket.com/user/poorboy_616/media/New%20Jeep/20160213_194111_zpsqyjyc6yt.jpg.html)

I noticed a tiny bit of wear on the ends of the shafts in my 8.25", but not enough to become an issue. Yours... look much worse. :O

New shafts aren't horribly expensive, but I would replace that cross shaft and lock bolt along with them. They wear on each other, so replacement is warranted on all of the components.

I replaced everything from scratch. It was the mechanic big fault. He grinder and cut the cross shaft 5mm so it fits inside the carrier and the cut part was installed toward the axle and made it worn by 3mm and when he filled that axle with weld he didn't measure how tall it should be. Weld was 3mm more and it pushed the carrier to the left and destroyed the ring and pinion.