11-29-2012, 11:08 PM
Usually on a thicker gear the case needs to be ground in that area. It is possible that the carrier preload wasn't high enough and the carrier was able to move some side to side. I'd just grind it a little more and checking clearance before re-assembly. I wouldn't be worried about it. Plan on new carrier bearings and ring gear bolts as well. They aren't that expensive.
Also, were you running a crush collar or a solid shim kit for the pinion preload? I'd get the solid shim kit. You won't ever have to worry about the pinion nut backing loose again with one of those. Get a couple of pinion nuts- 1 for setup of the preload shims and 1 to use when you get it set and finalized. You'll need a new pinion seal. Forget about the O-ring, it will be fine. I like the lube locker gaskets, too.
Also, were you running a crush collar or a solid shim kit for the pinion preload? I'd get the solid shim kit. You won't ever have to worry about the pinion nut backing loose again with one of those. Get a couple of pinion nuts- 1 for setup of the preload shims and 1 to use when you get it set and finalized. You'll need a new pinion seal. Forget about the O-ring, it will be fine. I like the lube locker gaskets, too.