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Well, good thing I am persistent. Even if I accept the slop as ok, I am more concerned with the discolored steel on spots on the carrier and ring gear. It is evident that it has gotten hot as some point.

I followed my instinct given the other issues I have found with the car, I quickly learned that everything is bad, until I prove otherwise.

I pulled the carrier and the bearings were heavily brindled. If I ran these bearings, I would quickly have had a rear end failure. I will march on with a total teardown and rebuild, only doing it once.

https://www.youtube.com/watch?v=e2TzzD_L2-Y

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Still working on the rear end. Silly me for trying to be practical. Purchase the exact bearings that I take out and pay the local shop to do the simple step, of turn two bolts to install a differential spreader, and drop the carrier in, tighten 4 bolts and check the back lash. Now, I don't mind paying for labor, but $850 is just nuts.

I have spent the past week doing extensive research since the seniors came with the rare and elusive Dana 53. For those who have not delved into the 53, they are the odd ball and very hard to find parts for a master rebuild. I have found a complete master rebuild kit that includes, crush sleeve, gaskets, new bolts, and gear goo to check the tooth engagement for proper alignment.

The normal kits for a kit runs under $200 but again with the magic words Packard, Dana 53, that kit is just shy of $400. Well worth it as it is a master kit will all the little parts. I have a housing spreader on order and will soon have a brand new rear end.

I talked to the tech department and spec'ed out the bearing races etc. and this is the kit. Once I get it and verify in person that it is exact, I will share the data for anyone else who is in need of work on the 53.

Next challenge will be U joints. Senior fronts have been all but unobtainium for years so keep your fingers crossed. I believe it is drive shaft conversion time if yours is so bad it can't be used but maybe there are other options.

IIRC one of our Australian friends had some issues and trouble finding parts for the rear joint to fix a leak. Believe he was finally able to find a different yoke and complete unit that would fit both sides with a little work.

Is this the same rear dif used on the 49-59 continental. ck randys ring and pinion. I had used them for parts many times always satisfied. was several years ago though.
http://www.ringpinion.com/b2c/PartsList.aspx?SearchMode=Diff&TypeID=3&DiffID=144&CatID=27

That would be the kit. I talked with Yukon to insure the kit has the same bearings that I took out and it does. I tried to save money as Autozone is a Yukon distributor and their kits are under $200 but the kits they list for the 40-50's Conti they list at the 9" ford rear all have smaller carrier bearings and wont work. I will have to pay the higher from Yukon to insure I get the right parts. I have a distributor right down the street that has the YK-D53 in stock and I will be picking it up this week.

Ok great. Good luck with it. I saw on earlier post you have the lock (posi) carrier. Seems the 56 has axle flanges and no shims for the axle end play but this rear dif uses shims under the side carrier bearing cones for preload and lash adj and shims under the pinion cup (race) for depth. I hope the orig shims get you right back within tol or you will be in for alot of pulling and pressing on and off and on etc. I am surprised this rear does not use side shims between the case and side brng cups which are much more pleasant to adj. Do you have experience setting up any other axles? Ford 9 still the best for strength and adjustability. Not 1 bearing or race need be removed to set up. My advice buy 1 extra side brng and 1 extra pinion rear bearing cup(race) and modify for slip fit for set up. Cheap addition considering the investment total. Dan

Yes, Diffidently going to do the slipper set for sure. I had one shim on the ring side and four on the locker side. Before removing the pinion, I made a gauge that will put the pinion right back to the same position.

I have set many M60 and M1 Tank Differentials but this will be my first car rear end.

I am tickled Purple, the rear end is completely apart and I had planed on going with a crush sleeve eliminator. Much to my surprise, it is already done, just spacer and shim on the pinion. This will make life even easier.

Axle is off to the sandman for a blast.

Hey Troy

I've been meaning to ask you.
You have meantioned a couple times your experience/backgrounds with tanks. Surely you have spent some time at Fort Knox. I just happen to be sitting there as I type this. Just curious.

Been there a time or two, but I was at Aberdeen Proving Grounds putting them through the paces.

Worked on the high speed track development on the M1. Toped out at 107mph before the track cut loose.