I have a 2013 express AWD and I’m replacing the axel seals in the front differential. While checking things out I noticed that the short side axel has some play inside the spider gear. I looked at the axel and it shows almost no wear. I looked inside and checked the spider gear and noticed it’s machined different that the other side and that’s causing the play. The gear is different that the other side. An engineer friend of mine said is it possible it is an engineered failure point if the diff gets in a bind…the top pics looks regular( other side ) the loose side looks double machined. Any help would be greatly appreciated..

This looks regular

This looks like it’s doubled machined

 

Looks double broached to me. Some idiot ran it through the broach machine 2x with a slight angle rotation in between. Find a replacement and swap it out or it will turn into a fuse, break, and put metal shavings in your diff.

 

Oh, tell your engineer friend he's an idiot. Signed, an engineer that knows some stuff but is still an idiot.

 

Thank you for the complete worthless information Triaged