The effectiveness of stress-freezing photoelastic technology was demonstrated in the design process of the Front Differential Carrier of the K30 truck. The technique offers potential for evaluating stress levels in structural components for which finite element and stress-coat/strain-gage methods cannot be readily used.The general process of 3-dimensional photoelastic modelling, its stress-freezing phenomenon, and the stress evaluation principle are discussed. Using layout drawings for the Differential Carrier and its mating components, the photoelastic model of the K30 Front Drive Axle Assembly was prepared. For an applied torque at the Driving Pinion, the resulting stresses were frozen in the model for evaluation. The high stress areas were identified and the slices from the model were examined for stress values. The distribution of stress levels through various cross-sections of the Differential Carrier was plotted and the effectiveness of reinforcing ribs was evaluated for the structural strength of the Differential Carrier.