Wanna go over some history about a Dana 30 I'm running. It was originally in an 86 XJ. When I put it under my 90, I did so because of the 4.10 gears (swapped the D35 as well)

The passenger hub bearing on the 86 D30 was toast...as was the seal at the vacuum disco.

I replaced the hub bearing, it was VERY VERY stuck...I actually broke a rented hub flange puller while trying to remove the old unit.

Instread of replacing the seal, I opted to do a one piece axle conversion. The outer portion of the 2 piece axle came out easily, the Inner some how got stuck...even after i removed the clip holding the axle into the spider gears.

I pulled the carrier, installed the seal next to the carrier, reinstalled the carrier and proceeded to install the axleshaft

It went almost all the way in, but something stopped it. I removed the carrier again to take a look. The spline end of the axle were hitting the seal.

I then decided to leave the carrier out and guide the axle through the seal. The axle shaft rode on the bottom of the seal and tore it.

I proceeded to remove the seal and notice the axle shaft was riding in a downward fashion...not centered. I tried to push up on the shaft to center it but there was zero movement or clearance. With the axle entering the tube this way and exiting into the housing at an angle...the passenger side hub bearing being toast and the seal being no good on that side...would it be feasible that the tube is bent on this axle?

 

Here's a view from the front...I even went as far as knocking out the roller bearing next to the disco housing. That helped a little but the way things are, I'd have to force things back into place.I'd likely ruin my locker,eat seals and destroy the replacement hub bearing...I tried assembling with the hub bearing on the axleshaft and without the hub bearing...makes no difference...things just don't fit...

 

Some of the early housings were jigged wrong and had excessive negative camber on the passenger side. You might have one.