Running into a little trouble rebuilding my D30. It's an HP and disconnect out of a '95 YJ if that makes a difference. I'm using the stock/original 4.10 gears and new bearings/races. Pinion preload is at about 22 in/lbs and I left all the shims the same on both carrier and pinion. There actually was no shim for pinion depth, just the oil slinger.

I'm reading various specs for backlash, most I find state .006-.010, some say .005-.009 and still others say .004-.008. None specify used vs. new gears or bearings.

I'm at .004 backlash. Am I ok? Especially since it's a disconnect axle? I didn't use set up bearings, was hoping the stock shimming would be right and I don't have a clamshell puller, so I'm afraid I'll bend the bearing cage if I try to remove the carrier bearings and re-shim.

 

I'm no expert, but maybe my response will bring out the experts to retort my idea.

I've only done two of these (front and rear). I followed the 006-010 as shown on my gear install manual.
I had .005 backlash and wanted to get my pattern closer to the heel so I moved a shim left to right and made it 008.
If I were in your shoes, I would probably rap it up and put some miles on it, then check it again. That's what I'll be doing with mine. Realize the difference could be grease or a speck of dirt, the dial indicator, or even the way your checking.

 

nothing wrong with running them a touch tight. Had some performance guys that say you can run as little as .003 back lash. Mine was .006 when I did my 4.56s and its been running great. Was that pre-load with the grease seal in? It seems a little heavy.