Differential Problem

Guys, I need your help again about my 2001 FLD.

The truck developed a problem with the front differential a few months ago. When I got it stripped, it was discovered that 1 of the bearing that hold the crown wheel hub was broken and caused the crown wheel to to lean on one side. There was no damage to the pinion only the crown wheel had one tooth chipped. Since I could not get a new crown wheel here the mechanic who was working on it advised that it would still move with the same crown wheel, and he assembled it back. (He also advised that it should be re-adjusted after a few thousand miles or as soon as it starts vibrating or makes any funny noise). It has done almost +8,000 miles since then without any problems.

All of a sudden last week, it started vibrating. And after driving about 60 miles, it started making noise and when the driver stopped to check he noticed smoke and oil coming out of the breather and the diff was very hot. I sent a different mechanic to have a look at it and suspected it could be the crown wheel or bearing gone. He the opened the diff and found that the crown wheel, pinion and bearings are all fine (except the crown wheel had the same chip). He found that the crown wheel and pinion had excess play. So he re-adjusted them and fitted it back. All was well and there was no vibration. The truck then continued with the journey, but after driving about 120 miles it started making noise as though something is loose or is breaking inside or around the front differential and it is locking. I got the diff removed again, and found that the crown wheel and pinion are all fine. I even disconnected the diff lock gear in the diff thinking it might be engaging into diff lock whilst moving. But it is still making noise and locking.

So far, I have checked the crown wheel, pinion and bearings but there are fine. Could it be anything else? Please help me with your ideas and suggestions.

It is a 2001 Freightliner FLD 120 with Cummins ISX motor, 10 speed Meritor Transmission and 2.64 Differentials.

 

Guys,

I still have my truck stuck on the road. We tried to remove the half shafts and engage the inter axle lock, but the truck does not move at all. We thought we could test the rear differential to make sure its not the faulty one. I thought that a truck would move with the rear differential as long as the inter axle lock is engaged.