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- #1,361
I just went out and checked my truck. At full lock to the left I have about 3/4" gap and at full lock to the right a little more at about 1". This is just an eye ball guess. The slight increase in size of the HD rod would not create that kind of interference.
I think you need an axle. Most likely why you had so many drive shaft issues and could even be responsible for the diff failure as the inner shafts are likely out of alignment and binding heavily under load.
I've never had a diff failure, nor any signs of, but have had multiple drive shaft configurations/issues.
This hasn't been wheeled hard enough, in my opinion, to have bent an axle, but I've only owned for a year and 6k, so can't say with certainty.
Wouldn't a frame shop have means to check?
If this is the case, would a built housing make more sense than replacing with OE, IF it's from wheeling, or a cost/strength perspective?
Have access to a front housing, now, if that factors into a logical answer.