Differential Pin Clearance

Ok, a few weeks ago I made a post about putting all the guts of a 31 spline carrier in a 28 spline unit. I wanted to know if anyone has done it or if it would work. Today I started my tear down. The center pins are two different sizes, so that was enough for me to say that it would not work.

So, I have my rebuilt 31 spline carrier out of the Explorer with the Carbon Fiber rebuild kit in it. Went to install it today, got .013 of backlash, so I'm good there. I then put in my brand new 5-lug 31 spline axles. Put on the c-clips, and pulled the play out of the axles so I could re-install the cross pin. Well, the cross pin won't go back in. Its hitting the very edge of both axles. I have looked this thing over a dozen times and can't figure out what the problem is. I'm running it through Google now, but no answers yet.

I rebuilt the carrier with the supplied shims and the spider gears went back in without any problem. So, whats going on here guys???? Somebody please shed some light on it for me!

Thanks,
Joe

No, running exact same 3.73's. Its not a gear problem. I didn't measure the side gears, they may be thicker. If I remember correctly, the shim and clutch pack was around .665" on each side. I'm fixing to measure the end of my new shafts and compare them to the stockers. Keep ideas coming!

Joe

Yes, it goes in without problem, does not interfere with s spring. I just measured the c-clip buttons on my stock axle. They were .249". The new axles are .300", so theres .051" difference there. I also just ran accross a post on Mustangforums where a guy was running into same problem, but he was using Alloy brand axles. He called their tech line and they told him that they are oversized and to file them down to fit. I am using Motive Gear axles, but I believe I am going to have to file them as well. I will keep you posted.

Thanks for your help!
Joe

I took .020" off of each and the pin slid right in. Hopefully this will help someone down the road.

Joe