OK guys,
I recently put a post in the "made in China on JD" thread and there's LOTs of chatter over there so now reading this post has me ready for a bit of a rant so strap yourselves in.
So every major company out there is buying food ingredients or tractor parts or doodads or whatever from someplace overseas. And then we buy this stuff ($100 cell phone or $16000 tractor or whatever) and it find out its low quality junk and say "Oh well" and throw it out and pay more $$$ to get another one. That's BS. I know the 790 is a good, rugged, reliable tractor, but Dan, you paid a lot of money for your 2520 with a full factory warranty. I'm sorry, but trading the 2520 for the 790 (in your situation) and possibly losing $$ is a dumb idea. I don't care about any stupid lemon laws.
There are only two possibilities, period:
1) Your dealer's service department is incompetent and has made the same screwup 3 times doing a simple repair.
OR
2) The "made wherever" axle housing has a casting defect and needs to be replaced entirely, meaning the whole darn thing.
I've been told many times that I'm laid back person, but after your second repair not working I would have been into that dealer, my neck veins popping out, demanding some action from somebody who can get that axle replaced. Another dealer in your area maybe? I have only had minor problems with my 2520 (nothing involving flooding my garage with fluids) and really love it (and my 455 too) but would honestly go to another brand if my JD service suddenly switched to being useless. My point here is that please don't let these machines become throw-away junk by accepting bad quality and bad service on top of it just because that's the way we expect it now in the "Global economy". I'm sure the local JD factory rep is eager to fix your 2520 axle problem. If not, we're certainly all doomed.