That's something I did not think about. Yes, I re-used the side and spider gears along with the carrier. I did inspect the 4 gears and they looked pretty clean and I didn't see any discrepancies with the carrier... although the human eye probably won't see all the problems. If the side gears were to gouge out the carrier, where would this happen? Would the side gears wobble within the clutch packs?

 

The new clutch packs will hide this from you. You would need to pull the axles and you might be able to check for up/down and side to side movement with the side gears with the carrier in the truck. I would just pull it all apart you are looking for play with the end of the side gear to were it goes into the carrier. So sloppy fitting side gears.

 

Well that's not good news... Thanks for the explanation. I have the axles out right now so I'll check for any play in the side gears but I'll doubt I'll find any without taking it apart as the clutch packs are keeping everything tight. When I was putting everything back together I didn't feel any play in the side gears, but I didn't inspect that part of the side gear either...

...disassembly and reassembly of the carrier was not the most fun task I've ever accomplished... actually taking it apart wasn't that bad but putting it back together took a thought or two...

 

They can be a right pita to get back together. Could be a good time for a upgrade to a locker of some flavor.

 

Lunch box locker or break out the welder..... IN order of cheap to real cheap.

 

I guess I should add if the carrier is gouged out it is your new door stop.

 

http://www.thedirtforum.com/differential.htm
This was very helpful when I had to replace my gears. Also I called East Coast Gear Supply to get the tool for the adjusters and it only cost me $35 plus shipping and I got it in 3 days. I also have a spec sheet if you pm me I can send you the info if you need it