you need to take alot of pics and do a write up, i think you've hit every problem posssiable and i think that would make for a good tech write up on this....
that and this is my next mod on my d44

 

Do you have to tap in the pinion shaft past the spacer's. I think my thrust washers are a little warped and It is a super tight fit. I think when I reinstall everything I will do the pic and write -up

 

Ordered front and rear aussies for mine on sat....watching this thread closely - cant wait for pics & writeup.

 

Well after taking a little material off the carrier I was able to get both cam gears in. So now that problem is taken care of, I got a new problem. The pinion shaft touches the spacers. I can get the shaft all the way in, but there is no gap, I have tried prying with a screw driver. I think it has got to be the thrust washers. Too bad they are not like shims, I could pull .003 off each side and be good. I am gonna try and pick up some new washers from the dealer tommorow.

 

Tampa, did you remember to put your spacer rings on your side gears before installing the cam gears? There should have been a step in your instructions to gently pry your cam gears apart by sticking a small straight slot screwdriver in the saml slit between them. Prying from the middle out to a.) prperly seat the cam gears and side gear and b.) to provide enough room to gently tap your pinion shaft through.

 

check this out for help if needed they did a pretty good write up on the sith for this install.http://classicbroncos.com/aussie_locker.shtml

 

dang, thats is a good write up, right click save

 

no problem just thought it might help

 

Well I finished it up today, I had to get new thrust washers from randy's ring and pinion cause the guy at the dealer ship thought I wanted a whole shim and rebuild kit. I did the little test and everything worked fine. But I will have to wait on a test drive till the morning. Next weekend I gotta go somewhere and try it out.

 

i just got my Aussie for my D30 today in the mail. Waiting for it to warm up[early spring] before i install it

 

If you have any questions let me know. I almost feel like an expert after all the time I spent on it

 

Tampa if you want to go 4wheeling next weekend let me know where you're going and I will meet you there.