Hi Burco,
It's normal to have a little backlash between the gears. There has to be some room for expansion as the gears warm up, and some more develops as the gears wear.
What about play on the pinion itself ? Try pushing it up and down or side to side.
The pinion bearing is directly behind the input flange. Can you feel any vibration with your hand at that point on the diff housing while someone is turning a wheel ?
I would think a failed u-joint or center bearing would be obvious after dropping the drive shaft.
Have you run the car with each rear wheel off the ground ? Does it growl, and is it the same on both wheels ?
Yes, I would suggest taking the cover off before buying a new axel. At this point it's only a gasket and you might find some evidence.
Peter
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