Measure Once, Cut Twice

It's been an interesting past couple weeks getting the Bromanche up and running.  From the beginning I knew that I wanted to put some sort of traction device in the rear axle due to the truck being 2wd.  Being  new to Jeeps I wasn't quite sure what this truck had, due to a missing build sheet, and me misidentifying a few key parts.  For the last 4 months I had been under that the truck had a smaller weaker Dana 35 axle under it.  I had also been hearing a lot of popping during turns, making me wonder if a factory limited slip was inside.  Upon quick inspection, by a quick spin of the wheels, I concluded that it did not, because the two wheels spun in opposite directions.  This usually indicates an open carrier.  I did not stop to think that it may indicate a worn out LSD.  Also when draining the diff, I didn't see any glitter in it, so I never bothered to inspect the spider and side gears.

Fast forward to a couple weeks later.  The popping is getting worse.  I decided to pull the cover again and take a closer look.  I find that the spider gears are missing a few teeth.  Since there was no bits of metal in the oil either time that I drained it, I can only conclude the previous owner pulled the cover, looked at the damage, and sealed it back up.  Thanks guy.  Earlier in the week I had also purchased a used Powertrax Lock Right locker of of NC4x4.  It arrived on the same day.  I thought that this device would save the day because the way that it is installed requires eliminating the spider and side gears.  Win!  I break out the tools and proceed to try to remove the cross pin to remove spider gears.  The pin binds on the ring gear.  WTF?  Turns out the gear is a 3.73 as opposed to the 3.05 I anticipated and was thicker causing clearance issues for the cross pin.

Ok, what the hell is going on?  I thought only the D44 came with a 3.73 ring.....well crap.  I jump on to the interwebz and start looking at what all the Dana axle diff covers look like.  We have a match, and it's not the D35.  Sweet, I have a D44!  Crap, I have a D35 locker.  Upon further inspection, it does indeed contain a broken LSD.  Ok, what can we do?  Maybe I can buy a locker to replace the LSD.  $650?  FML!  Ok, how about replacing the LSD carrier with an open carrier.  Nope, will require a 1 ton press, a 375 dollar bearing puller and setting up the gears.  Looks like we are going to have to rebuild this LSD.  Oh wait, spider and side gears are nearly impossible to get.  On to ebay, I pick up the parts I need.  Great, I just paid more than the old locker for less performance.  And, now we wait for the brown Santa..