99 TJ rear Dana 35 rebuild problems

[99greenTJ]

We rebuilding the tired rear end and all went well until trying to install the pin in the case.
The pinion pin has to be tapped with to much force. It will go but there is no clearance between the tips of the axles and the pinion pin.
The axles I bought we from rockauto, pn 923129 and 9231290
The only thing is I don't has abs and these axles were abs ready but no tone ring furnished.
This problem is maybe,.020 thousands issue.
The axle drive end C clip tip is .020 approximately thicker on the new axle. The actual C clip area is also shallower on new compared to old.
Old C clip clearance. 028, the new only .013, with clip in place.
This appears to be a machining issue, not sure, asking options.

 

[machoheadgames]

Can you sand down the ends of the buttons to take off the 0.020? When I did mine I bought my new shafts from Spicer, they basically perfectly matched the originals.

 

[99greenTJ]

Sanding them down is something I have thought about. Want to see if anyone can see any red flags with what I have and done.
Send the axles back for an exchange isn't a sure deal I think.

 

[machoheadgames]

I can't think of anything wrong you could have done to cause this. The side gears are what they are, and the pin is what it is. No trakloc involved in any of this correct? And you're just reusing stock carrier? ABS shouldn't be an issue from what I recall, you just won't install the tone rings since you don't need them.

 

[99greenTJ]

Yes reusing the carrier and ring and pinion, all else new.
A note, the old side gear shims were thicker than the new.
The ABS is just something I wanted to clear as not being an issue.

 

[99greenTJ]

Update, filed off enough of the end of the axle, to allow the pin to be inserted thru the pinion gears.
It was close, just needed some massaging.
Hope others don't need this mod.
Thanks for help