Quote from: fordem on May 30, 2012, 03:04:29 PM

I think you need to find a new "advisor" - who ever is looking at the stuff seems to have very little more than a basic knowledge of what they're doing - and sooner or later you are going to be led seriously astray.

Nothing in the rear axle is related to the speedometer - the speedometer is driven by two gears in the tailshaft housing of the transfer case - those gears do need to be matched to the final drive ratio in the axle.

The "teeth" on the carrier are most likely part of an ABS (anti-lock braking system) speed sensor - and it would be extremely unusual for them to wear since nothing is supposed to come in to contact with them - nevertheless - carriers do wear and are replaceable.

If that 95 Tracker had been a 95 Sidekick I would have been only too happy to provide you with the part numbers, and a dealer who would probably have them in stock.

You are correct on getting a new "advisor" it is the carrier that has to be replaced. the teeth are all perfect its the CENTER HOLE that is "wore out" i will have to post pictures to better explain myself. never the less, is there ANYWHERE that you know of that i can get this part. i called a dallas, tx rear end place and they said i can not get just that part it has to be the whole housing and it will cost me 700 bucks...no bueno. =(

So it is the hole in the carrier, that the crosspins slide through/into, is what is worn?  I have seen it happen before on samurais, that were ran low on oil in the axle.

You could get a used thirdmember (a thirdmember, or third, will consist of the complete assembly that contains the gears, carrier and center housing), that bolts right into the axle housing.  That would likely be the simplest and cheapest way to go.  The only thing you have to watch out for is to make sure the gear ratio is correct in the replacement third.  According to the info you provided, you need one with 4.30 gears (they will have 10 teeth on the pinion and 43 teeth on the ring gear).  The problem is, 4.30 thirds are not real common to find, but they are out there.
I would guess you should be able to pick up a complete third with 4.30 gears in it, for around $150 + shipping.

edit:
Reading your post that you posted while I was typing this one, it sounds like it is the side gears that are inside the carrier, that are worn (which is kinda uncommon for them to wear enough to cause issues).
So other than the axle shaft being bent (and possibly the axle housing being bent), what makes you think there is anything wrong inside the thirdmember?
Can you take and post a picture of the actual part that is worn/broken?  I want to see the actual worn/broken part.

It might be simpler to get a good used 12 bolt differential and swap the ring gear over.

One thing to bear in mind - and I have no issue here with your being a DIY girl - differentials are not for beginners, most of us (me included), lack both the tools and the experience required to set the gears up correctly, and with differentials, if it's not setup correctly from the get go, it'll be noisy.

Heck, just get a rear end from a Manual tracker that has the ABS sensor and swap the entire rear end.  Don't even bother taking it apart.

Take a look at the FSM (Factory Service Manual) on Acks Faq. It actually walks you through rebuilding the entire differential and how to set it up.  With a feeler gauge and a couple good torque wrenches you can get things setup, just time consuming.

You are correct on getting a new "advisor" it is the carrier that has to be replaced. the teeth are all perfect its the CENTER HOLE that is "wore out" i will have to post pictures to better explain myself. never the less, is there ANYWHERE that you know of that i can get this part. i called a dallas, tx rear end place and they said i can not get just that part it has to be the whole housing and it will cost me 700 bucks...no bueno. =(

Pull A Part & local yards will sell you complete rear end assemblies for |removethispart|@ 1/4 that price, with a small warranty.  If you check with Craigs List you may be lucky enough to find someone parting, or upgrading gears (for larger tires) for even better prices.
I would up grade both front & rear to manual gears 5.125, but that would be a big step unless you already have larger tires.

Your problem with changing Ring Gear & Pinion gears in present diff is going to be

• Still need side gears
• Getting pinion flange off to remove pinion gear (usually needs a press to remove)
• Crush sleeve usually needs about 200-250 lbs/ft to start crushing (do not need torque wrench for this, just strength), then you need an inch/lb torque wrench to measure rolling resistance as you continue crushing sleeve

I would suggest you swap in whole third or have a shop make the RG&P switch (for peace of mind).