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For all you differential guru's out there, I need some advice. I have the following end play on each of the side yokes 0.072" and 0.052" so looking to address this. One thing I thought of was to weld hardened washers to the side yoke tips of the appropriate thickness to take up the end play. Also looking at the Diff cross pin through the side yoke holes, there appears to have flat spots on each side through contact with the side yokes. Is it possible to remove the cross pin, turn it 90° and re-insert it? This would also take out some of the end play. See attached pics and tell me what you think.
Also the material on the end of each side yoke is about 0.175" from tip to snap ring slot.
The cross shaft is worn. Some of the new shafts are not hardened correctly, at least the new ones I purchased and tested. I have Tom's shafts and they are correct. In fact, I am going to have hardened and ground shafts made and oversized for a polish fit.
The axles don't look too bad, they should be checked for hardness but if original C3 axles they are only good to about 50kmiles before the case hardening is worn away. .175 is worn. The rest of the play is in the posi set up. You want them to be 005-007 but up to 010" is ok. No tighter than 005".
A stock posi is not balanced, uses a spring pack and typically are not dialed in correctly. The spring pack will compensate for production assembly and common rebuilt posi's. The case needs to be checked, and the clutch type is important.
A tuned posi, correctly done, is much better.
Differential side yoke wear
