Here is an odd one I noticed a wet spot under axle figured it was front seal but after inspection its leaking from the housing in two places. Now the question is can I epoxy the leak or more likely replacing the complete axle assembly?

Truck is a 2003 3500 Diesel 84000 miles approx.

What years would cover as a replacement 2003 to 2010?

 

Wow, that's really weird, coming right out of the housing like that. Can you see a crack, or is it just pitted? I can't tell if it's the front axle or the rear.

I would definitely give epoxy a try before going to the trouble and expense of replacing the assembly. I think prep work would be the critical part- draining the housing and making sure all traces of oil are gone so the epoxy will stick. I have found that spraying the surface down with brake clean and blow drying it with compressed air (repeatedly) gives good results, and even cleans out the porous spots well. Using a sandblaster to clean the spot down to bright shiny metal might help you to see exactly what you are dealing with, too.

Hope it goes well.

 

It's the rear there are two holes one is directly on the bottom of housing will try epoxy and fiberglass over the patch.

 

Sorry posted in wrong section should of been in the 2003 - 2007 Engine and Drivetrain could an admin please move. Thanks

 

I would be hitting the wrecking yards for a complete replacement. It looks like housing maybe cracked or porous topped with corrosion.

 

Your probably correct I will begin calling Monday and see if i can find a local axle. There are a few online but many need to be shipped to a business address which I don't have.

 

Hate to say it but I would try welding it with a high nickle rod before I got too crazy. Drain, clean and you shouldn't put very much heat in it at all just filling a void.

 

Got around 5 pounds of rust off housing still not all off afraid to find another thin spot. Will seal holes so I can get it to a repair place when i find a replacement axle, would hate to fix and have a major failure while towing or on trip.

 

Yep that's the biggest worry. If rust has attacked a housing that's that thick, it makes sense to just find another one.

 

Whoa, the housing itself is rusting?

That's a new one on me, I can't honestly say I have ever seen a housing rust away, perhaps a bad load of iron?

If you took that much rust off, I concur, replacement is only good option.

 

A new assembly does not exist anywhere, no longer serviced by Chrysler, I have the local Drive Train Specialist looking for a used one.
none of the local used parts in the area have one 2003 to 2005 will work.
SRW is harder to find guess I should of got the 4x4 version.

 

Ordered axle housing from LKQ online parts should be delivered the 25th will have work done after thanksgiving.

 

Saw the housing today looks perfect and have appointment for install for the 3rd of December. Housing came with a good set of rotors also.

 

Ok replacement axle installed DTS did a great job the final total cost was $1000.00 (axle + shipping and install 1 day) I hope all you other 2003 3/4 ,1 ton guys don't have to go through this. DTS has done 5 or 6 of these already not all 2003's.

 

You got a great deal you should be very happy with that price.