This is for the 8.2" 10-bolt. I'm not sure if there are significant design differences between it and the unit for our 3rd gen 7.5/7.625", but thought I'd pass this on.

I put the Powertrax in back in 2001 when I still had stock 3.08 gears. When I had the 3.73's installed in June '02, the shop wanted me to pull the PT, axles & brakes (this particular shop doesn't work on cars, just rears). As the fluid drained, I noticed a very small metal chip laying in the bottom of the case, for which I never identified the source. Overall, the PT unit looked very good, not much different than when first installed. Couldn't see anything wrong with the gears either, but since new gears & bearings were going in, I didn't worry about it much.

I pulled the cover again last night to change the gear lube for the coming season. I found an identical chip (great memory, huh?). This time, I noticed that the end "cog" on the drive dog, right at the "flat" of the unit, was where these chips came from. A small corner was fractured off from each side at the flat. Had they just radiused that corner, it would look pretty much as it does now, with no effect on unit performance.

I didn't pull it to check the other side (can't see through the carrier), so I'm not sure if a similar condition exists on the other flat. I've been beating this poor thing at the track for the last 3 seasons, so I suppose you could say no worse damage in that time ain't bad.

Thought I'd let you know about it, though. Again, don't know exactly what the 7.5/7.625 unit looks like, but I'd guess they're similar designs.