Quote Originally Posted by DennyW View Post
Did you double check any play between the pin, housing, spider gears, and bolt. That usually is the problem. Have replaced a few over time. Nice kit.
Yes, there was no play in the carrier. From the Extraction Kit site (Link - KIT INFORMATION ) :

Mechanics estimate 80% of differential pinion shaft lock bolts (sometimes referred to as a cross pin, locking pin, or retaining pin) are found in a broken state when servicing this type of rear end.
I'm convinced that this is a combination of a marginal design by the OEM, plus 131,000 miles of trouble free operation. The lion's share of these c-clip rear ends (other than those in Jeeps seeing off-road duty) never have the rear cover removed, and the locking bolt breaking is of zero consequence to continued safe operation. The threaded portion of the bolt remains torqued in place, trapping the fractured pin, and the pinion shaft remains securely locked in position. The only issue is an internal failure or leaky seal that necessitates pulling it apart, when the broken pin is discovered and Catch 22 is applied.