I have an 81 truck but I believe it has a front axle out of a 79 or 80 because there is no axle gussett. Anyways to the problem at hand. I have noticed a slight vibration coming from the drivetrain but only in 4wd. I decided to change the gear oil for routein maintenance and discovered large amounts of metal shavings on the drain plug and in the oil. It was enough where anyone would know that it was not normal. (rear axle was fine) My mechanic has changed the gears in the front once (from 5.29 to 4.10) the second time he changed to 4.56 along with an ARB locker. Never any problems before with the other swaps. Two things I wanted to note is that the locker and 4wd still works as should, and for some reason we had to use a puller to get the front axles out of the housing everytime we changed gears. Yes we did have the flats on the birfields lined up correctly. Has anyone had an issue like this before with these trucks. Any help or insight would be apprieciated. Thanks

 

79-81 no gusset, 82-83 has half gusset and 84-85 has full gusset.
You have a bent axle housing.

:wabbit2:

 

^^what it sounds like to me as well? shouldn't have to use a puller to get them axles out

 

my 81 had a half gusset...
x2 on that bent housing, best be looking for a new one.

 

Here is how you can double check to see if it is bent (which it probably is) Measure from rear tire to front tire on each side, and if there is a discrepancy... it's bent...

Now is the main housing bent or just the knuckle balls? My front knuckle balls are bent and I have to cut those off, weld on new ones AND get a gusseting kit. Wabbit, do you sell those kits?

 

I was thinking that could be the case. Both axles (including the short one) are hard to remove so its probably the knuckles. I do have an 82-83 axle at the shop I can build. One thing I did notice is that my passanger side hub is not unlocking. Do they make rebuild kits for the stock aisins? I just hope the metal shavings are from my ring gear and not my arb diff.

 

This is what my ARB looked like when I pulled the third to have it rebuilt. Apparently this wear on the locker is fairly common. After researching it a little, I found that there is no cause for concern. Since the rebuild however, I have changed the gear oil 4 times; every 500-1,000 miles. The last time the gear oil only had minimal shavings, like normal. I'd be interested in seeing a pic of your locker after you get the third out...

 

Wabbit refurbishes Aisin's.

 

Have not had a chance to pull it apart yet but have resourced some good parts. I have a complete 82 axle (from hub to hub) but have found an 85 housing for $100 bucks. Figured the full gusset is worth the extra money. I hope if im lucky I can get out of this jam on the cheaper side. I will be getting the gussett kit for the knuckle balls aswell. Since I am using two different axles to complete one is there anything that I should look out for during assembly to make sure it goes together correctly? Thanks for all the input so far guys!

 

where are you at I have an 81 housing I need gone you can if you come get it Im in CO

 

I have already found an 85 housing. Im in SC. Thanks for the offer though.

 

Where at in CO?