I have gone through several right side axles on my TJ. I have replaced the first axle about two years ago when the seal was replaced. There was over 1.5mm wear. Because I was stuck on a long weekend in a small town, I installed a used axle with its bearing which was not pitted or worn. During this process I noticed that the axle in the jeep was replaced before.
About 3000 miles later I had to swap out the replacement axle. I replaced both axles & bearings (Alloy USA kit), pinion bearings, yoke and seals.
This lasted about 15,000 miles. I have the same aggressive wear problem on the right side only.
Any ideas why only the right side? The housing does not appear to be bent or cracked. Is this a Dana 35 problem? Where should I be looking for the cause of the problem?