Drivetrain Clunk.... I'm at my wit's end

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Is there a crack in one of the original pins? looks like in pic.
No, pic doesn't do it justice i'm afraid. Condition of pins and gears was ok. Copper washers had totally disintegrated. Installed new center pin (HD) and new copper washers.
 
I created a new thread describing how the center diff feels after the upgrade when the front or rear flange is turned by hand.
 
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