I bought new OEM spider gears, side gears and cross pin. The diameter of the new cross pin, looks undersized. The ID of the spider gears is .757, the OD of the cross pin where the spider gears ride is .747. The OD of the ends of the cross pin, where it rides in the carrier is .746. The ID of the holes in the carrier is .754, . this seems like excessive clearance in all these areas, and leaves the spider gears without any real support from the cross pin. Would it be a bad idea to machine a larger diameter cross pin, say .751-.752? I would like to hear your thoughts, and your replies would be appreciated. Thanks. James

 

Just put it together & don't worry about it.
Those sizes are right in spec. Any tighter and the gear oil won't be able to lubricate properly & you'll possibly end up with a seized cross shaft.

 

Good advice! Yeah, I was worried when I saw the old broken gears. The clutch pacs were worn out, everything was so loose that I was able to push the S spring out with my finger. Thanks. James

 

The S spring was a challenge to get in past the 4:10 ring gear, I compressed it in a vise and wrapped a piece of coat hanger wire around it and twisted the ends, that held the spring compressed, and I was able to slip it in far enough to tap it in.

 

I have a little over 300 miles on the rebuilt rear axle, seems to be working fine. No problems from the clutch packs, everything worked smooth right from the start. I soaked the clutch packs over night in gear lube, and added about 2.5 oz. of friction modifier. I stacked the the clutch packs, DD,CP,DD,CP,DD,CP,DD,shim.