[Jack Hidley]

All you changed here are the axles, correct?

Assuming the axles are 28 spline, the button thickness should be 0.249". The groove width in the axle should 0.167" wide. Many aftermarket axles are machined incorrectly.

Don't grind on anything. Just use some old friction discs to slightly reduce the overall thickness of each of the clutch packs. This is one of the good reasons to keep all of the old discs.

 

[tooler]

<--- mechanical doofus

All it took was lubing the axle ends and cross pin and then moderately prying the axle ends apart with a large screwdriver. I didn't even have to push very hard.

You never hear about this on the Internet because most guys have basic common sense and tried that first!

Oh well, sorry for the alarm. Hopefully my story will help someone one day.