I have been rebuilding a particular make/model of FWD manual transmission. Some of these trannys consistently eat differential bearings, and I haven't yet found any reason why.
I suspect the aluminum housings are either machined incorrectly, warping under heavy load, stretching under heavy load, or all of the above. So that the bearings end up misaligned and wearing out prematurely. This is my theory.
At work we have a wonderful CMM machine that can measure the bores, locate the centers, verify face runouts, etc. It would be perfect, but our company has a very strict policy against personal use of equipment. I fear that contracting someone to CMM it would be exorbitant.
I would love to measure them myself by hand - I have depth micrometers, bore gauges, and 12" dial calipers. But the bearing bores are at all different depths relative to the machined face where the housing is split, so my hand measuring tools appear to be of no obvious use.
What kind of cheaper approaches might work to measure the bearing bores for position, depth, and face alignment? What kind of machine shops might be able to measure them for less than the cost of a new housing?