Trip, when you say the clutches and bearings were about to explode, what exactly was wrong. Were they worn out, tore up, or what. Fortuneately my truck has stopped making the noise after I changed the fluid. I don't doubt there could still be a problem, but I am still under warranty for the moment, and my problem has been listed as a GM case number.

Quite frankly I am hoping my explodes. I would love to have it towed into the dealer, and then tell them "hey get to work", here is the axle you told me was perfectly fine.

I looked at the rear axle when it was out of the truck disassembled. The bearings, races, and clutches were all pitted like it had water damage and the bearings were all very loose. In addition, the planetary assembly was very tight and they couldn't believe that it didn't shatter yet. There was no water in the differential fluid they drained so that wasn't the problem, it's still a mystery. There was also metal shavings in the axle housing.

I haven't seen the bearing races this time because the dealer didn't even bother disassembling the rear end. I did see the inside of the axle housing and it had metal shavings in it again. They just decided to replace the entire axle once again.

The first replacement axle was one that had under 1k miles on it. This time, they found another axle with under 6k miles but the thing was completely rusted and I wouldn't allow them to install it. After complaining, the warranty company finally agreed to a brand new axle. Hopefully, this is the last time!

As long as your problem is documented, you should be fine if it fails in the near future. I noticed my problem initially after driving a long period of time (Wisconsin to Oklahoma). I pulled into a hotel parking lot and the thing started making the growling noise in the turn. Perhaps the oil is breaking down when its hot?

Why was the Dana rear end used instead of the GM locking diff that's used in all of GM's HD trucks?

Well I am off to the dealer tomorrow. I know I said I was going to wait until it exploded, but the last two days it has been loud enough to grab poeples attention when I drive by. Not exactly a feature you wnat on your luxury truck.

I am also going to have them look at the steering. There is for lack of a better work a cachunking in the steering wheel. If I am lucky hopefully it will be the intermediate shaft everyone is talking about.

My axle seems to be worse after traveling on the interstate or at high rates of speed.

Thanks for the reply, that also leeds me to beleive that this is not a trivial problem and I need these guys to open up that diff and figure out the problem.

Could we maybe try and work out if this grinding problem is happening to certain models/years or is it right across the whole range? As far as I understand, the rear ends were all the same anyway - all Dana's - but maybe they were assembled in several batches and maybe there was some changes made (like they ran out of correct fluid one day, so just filled them with whatever was laying around ) j/k

Anyway, if you are having the problem or know someone who is - maybe list your make/year/month. If enough people resond, it may prove to be a useful guide of what to look for and what to stay away from, especially for me who can't just take it to a dealer, well not unless I drive it on a ship............ $$$

Well as far as the date is concerned, is there a place on here to cross reference my VIN to get that info?

Well I thought everyone may want to know..... The dealer is in the process off changing out my inner axle assemblies, on the rear axle. The bearings were extremely loose and fluid was leaking out around the CV joint. It was a mess. I hope this solves the noise problem!

OH AND BTW he said the new assembly was a new design!!!!!!!!!!!

Anyone have any info on this. This may be the answer for lots of people.

Dave, I hope this finally solves the problem for you. I didn't catch it in the thread, - what year and model you have?

2003 Sierra Denali, On a side not a buddy of mine took his in, for routine maintainence. He told them that he had noticed a little sound also. Sure enough they saw the beginning stages of the failure that happened on my truck. They are also ordering axles for his truck.

Dave, thanks for keeping us posted on this as it concerns us all.

New design, eh? Is there a part/assembly number change that will differentiate between the old bad design and the new fixed(?) design?

Hopefully this new design worked its way into later models.

Anyway, to help everyone sort out who had what problems with which vehicle and what, if any there solution was, I put together the following.

Let me know if it needs updating.

This message has been edited. Last edited by: Oddball,

You know guys, what I'm seeing here is that the rear axle grinding issues seem to be on the 1/2 ton extended cab models. Mine made thunking sound like tire tread rubbing on the body or frame, but nothing like a grinding noise as Trip describes.

The 1/2 ton's have the smaller rear axle than the 3/4 ton trucks right?

Like I said before, what was wrong with using a modified standard locking diff that they have used in millions trucks instead of a Dana unit?

Good point about the 3/4 tons. Mine, yours, Mr.Qs' are all 3/4 and none had problems. If Awphil03 chimes in with the reason his was in was maintenance only, then we'll have a small concensus and can rule them out.

Maybe THAT was the new design DAVECS2 and his buddy got installed, - 3/4 ton axle.

Another coincidence is that the guys with the problems had Denalis with what I believe were all 4:10 ratios.

Oddball that is a great spreadsheet! I have my truck back. I must say it rides as smooth as it ever has.

I do not if I am used to hearing things or there is still a noise in the back. Let me state though that the groaning has STOPPED. The noise I get now is like brake bads hanging up on a drum or rotor. It is a cyclic rubbing noise as I pull away from stops. It is really quite and it can only be heard if the HVAC and radio are off and it is not windy out. I know I am overly critical.

My buddy's first name is Alan. I will get him on here. He has a 2003 Denali as well.

Here are the part numbers that were installed on our trucks. We cannot seem to find to much information on them

15115915

Looking at that part number leads me to believe that this part is not a new introduction to the GM parts system. I think all new numbers start with a 2 or better Also the information I have found leads me to believe that this is just a hub knuckle assembly, not axles.

On a positive not I recieved the new steering shaft part number 89060582. That part made a huge difference in the feel of the steering.

I have been ashame to chime back in with the cause of my squeeling. 28 PSI vs 34 PSI.

This topic has evolved way beyond my problem.

Heyya, Gang. Been kinda down and out all week

Sucked.

But much better now

Sean, great spreadsheet Man, I can't thank ya enough Very cool.

I hate to bust the theory... but mine's groaning like hell Lemme double check my tire pressue (good catch, Strap), but I check all of our tires pretty regularly, so I'll be kinda shocked if that's it. And with the way it sounds and feels...

But, mine was also involved in an accident, directly in the rearend, so that could have A LOT to do with it

I'll let ya know what they say. My warranty is just about to expire, so I'm glad it's surfacing now !!!!! 5k miles from now and I'd be SOL !!!!!!!