I was checking out a front end noise and found that my front diff has a bunch of play at the driver's side output shaft. Can this bearing be changed from the outside or does the diff need to be removed and disassembled to do this? Anyone tackled this job lately?

 

You have to disassemble the diff. Once you are in there you'll want to do all the bearings. Pinion and carrier. I'm bet a carrier bearing failed and allowed the locking tab to break and the adjuster backed off.

 

This is very common, and an issue that I currently have. I plan to swap from 3.73's to 4.10's when I can afford to do mine (my G80 is broken also )

I believe that the locking tab is what breaks first though, allowing the diff to rock around in the carrier and the bearings to eat themselves...

 

That "play" you are noticing is likely normal. Don't be surprised if you rebuild it and it still has the same play.

Adding pics...

The bearing would be #58 in this pic. You do have to remove & disassemble the differential to replace it.


This pic just shows the style of the bearing, not the actual bearing. The only other thing that supports the left stub axle is the side gear inside the differential case.


Every single left front stub shaft I've paid attention to has up & down endplay when you grab it and pull on it. The common front differential bearing failure that these trucks get has to do with the lock tabs breaking off, and allowing the adjusters to back off. Takes out the diff side bearings(carrier bearings) first, then eats the ring & pinion. In the above diagram, #46 is the adjuster, and #47 is the lock tab. #33 and #34 would be the diff side bearing & race that get destroyed when the lock tab lets go of the adjuster.

 

Great info, thanks guys!