I have this Dana 70 I am rebuilding for my Ramcharger project, the drivers side housing has the spun bearing cup damage. I haven't been able to find a shop with the tool to fix the wear damage, if anyone in Alberta knows someone with the tool, it be appreciated. I looked at some other housings, and they all have this damage.Being 93 and prior and they are old parts, and cherries seem none existent.

Hard to tell in the pic but im not sure that's damaged vs maching marks. The surface for the od of the cup looks ok. How does the old cup look?

Is a new cup a loose fit?

Was backlash excessive originally?

Ring and pinin destroyed from the backlash opening up as the cup wore into the housing. The back side of the cup was wiped from rotation.

They make flat round shims for that.

I thought about shimming it out, a local diff shop said they've had no luck with doing that and won't do it as the bearing wears prematurely as there's no guarantee it's sitting true as the ridge matches the old cup footprint. They do complete banjo replacements instead of trying to fix the surface, which is also big money.

It looks like theres a burr on that outer edge and if it was even all the way around I would just take a dremel with a stone wheel carefully to it so it was flush, I think this was discussed before and there is a grinding wheel on a rod device that can be inserted thru the axle that can be used to touch that up. The bearing won't care when its pressed in next to that area if it was parallel to the other side

Down in the saddle there are is lip as well.

Here is a good explanation, my diff falls into the "severe case" category.
https://torqueking.com/dana-spicer-rear-drive-axle-component-failures/

I'm not talking about shimming it out. They make a spacer that will go in between the race and the housing that prevents it from wearing the housing.

This is already worn on both sides, a spacer isn't going to fix the problem I have.

The spacer is actually made for this problem. They come in different thicknesses.

That still won't work, as the ridges aren't even all the way around, the spacer wouldn't be sitting true in the bearing bore against the face, which means the cup would be cocked, the ridge has to removed so its flat and the flat has to be true, 90 degree from the saddle, which its not now.

I know the 70hd and the 80 have the spacers the bearings sit against, the 60, 70 and 70u don't.

I am going to look at another housing this week, failing that I'll probably buy the 700.00 tool to machine the surface and be done with it.

I think I found what you are talking about its part DS42563, its a spacer if you have a Wide 60 carrier and are fitting a narrow case into it.

How far are you from Eureka or Sweet Grass MT?

You can borrow my tool if you return it in a timely manner.

I am about 3 hours away from there.

I can ship it to the border if you like. Otherwise it may incur brokerage fees.

If this other housing is pooched, I can drive the housing down to you and have a Montana weekend.

I went through 2 more housings, all have spun races and the side wear. You can pretty much tell right away as there is no effort to remove the carrier, it will fall out as soon as the main caps are removed.
Digging through the scrap pile though, I found a Dana 60hd with a suregrip LSD that's usable.
I will need some parts for it, doctor diff is pretty close so I'll be ordering some from him.

A local machine shop in Calgary was interested enough that they put together some tooling to repair the Dana housing type wear.
Aztec machine did it, sandblasting, painting and reassembly next.

Thanks for the update. If I ever come across this problem, I'll know who to talk to...

Nice!