Diff build w Yukon dura grip....cant get C clip back in

[Leverhead]

Hello all. Have an interesting issue with my 64 fleetside 1/2 ton. Rear is a '65 30 spline open 3 :73 and needed a rebuild so went with Yukon LSD dura grip and new motive gears (3:73 again). Got it all set up and cant get the c clip back in the driver side axle....spring plate is in the way. No issues with axle seal or bearing...just seems to have run out of splines and cant get the axle in any further.

Used the same carrier in my 75 blazer w no issues....longer axles but same 12 bolt housing. Yukon lists this carrier for all 12 bolts 65 and up.

Pic attached...going to make some calls. Will post findings.

Any have this issue before with a posi unit and how did you overcome?

[The Rocknrod]

Wow, so it's a heck of time to ask but are they the same length axles?

[Leverhead]

Yes ...same length...30 3/4. I've switched both sides. Same result.

Called Yukon...they said they get calls about the clutch plate being out of alignment and blocking the axle. Not the case as the axle has already passed the plate. The center pin was in the entire time I set it up so it cant move. Then they said to contact the retailer.

They also said to remove the spring assembly with big pliers or something but I dont think that can be done while the assembly is in the car with the ring gear installed.

Called retailer but now they are out of the office until Mar 15.

Going to pull it this morning and check if there is something blocking the axle ...like bad machining on the side gear (splines) or something.

Thanks for responding

[The Rocknrod]

Originally Posted by Leverhead

Yes ...same length...30 3/4. I've switched both sides. Same result.

Called Yukon...they said they get calls about the clutch plate being out of alignment and blocking the axle. Not the case as the axle has already passed the plate. The center pin was in the entire time I set it up so it cant move. Then they said to contact the retailer.

They also said to remove the spring assembly with big pliers or something but I dont think that can be done while the assembly is in the car with the ring gear installed.

Called retailer but now they are out of the office until Mar 15.

Going to pull it this morning and check if there is something blocking the axle ...like bad machining on the side gear (splines) or something.

Thanks for responding

Yep, it's got to be something like that.

[Leverhead]

Took it out and set it on the axle....no shims or bearing cap....Groove for clip just clears. So it seems with the bearing cap and shims installed, the clutch pack and spider gear combo are jutting out so much as to block any clearance for the c clip. pic attached

Shims are @ .074....avg to less than...time to call yukon again.

[Leverhead]

Talked to Yukon rep again...says I have to handle it with the retailer. .....and they are out for 2 weeks. Soooooooo.......

[The Rocknrod]

I didn't, but I'm just one guy so who knows really.

[nsb29]

I just did mine with motive 3-73 gears don’t remember the manufacture of my limited slip as I replaced it 8 years ago and there’s no manufacturer markings but had no such issues. yours looks like a series 4 Carrier what is your back lash also how much shim on passenger side versus driver. I’m no gear guy and had my share of problems but don’t understand why you could get a clip on it out of the housing seem like sum thing isn’t centered, pwith the C clip in place on passenger side is the seal riding on the axle where it should be I’m sure you have made sure that the seal on the driver side is installed all the way and not holding you up

[350TacoZilla]

I could see 2 possible fixes. 1. could be done at home and 2. would require the help of a machinist.

1.Could you grind a bit of a ramp into the side plate so the clip slides in? In pics it looks like its just a combination of that plate thickness and the shim pack screwing up the alignment, no worries of the clip falling out later since the center pin would hold it in.

2. Have a machinist make a shim for the ring gear instead of shimming the carrier, basically slide the carrier back over tight against the housing and just shim the ring gear to get gear mesh instead of carrier, then shim passenger side of carrier enough to center it.

[nsb29]

I think the problem is in the carrier he has used that model and manufacture with out a problem. they make a spacer so you can run a series 4 gears on a series 3 carrier but in this case it would just show up on the other end.
But I’m not a gear guy

[PJ66C20]

Is the axle bearing pressed all the way on?

If it is, and Yukon says they have an issue with that, which sounds like a BS answer on their part, maybe you can make a small spreader or a way to pry against the springs to pop the clip on.
Or, even better would be to install C-clip eliminators. Then you'll never see your wheel and axle passing you after a good burn out.