BTW, what was your measurements? My shaft to axle was .011 to .012, and my inter cam was about .135, about .010 below the recommended min. Damn, those thrust washers are strong!!!
I do not remember exactly what my measurments were. I belive that they are in the email conversation with Aussie in the write up thread.
I do know that they were much tighter then the toloreance specs supplied with the locker. This was due to the thrust washers being thicker then the TJ and the cupped shape. Speaking with Aussie they said they like the d30 being set up tight anyway as they have had SOME issues with it unlocking on the TJ. They suspected the JK washers with thier cupped shape would relax over time.
I noticed no changes till somewhere around 4k miles later. Now that they have relaxed they are perfect and rarley "pop" when they unlock turning sharp corners now. BE prepared to have some popping turning sharply in parking lots for a while. FWIW, I have never had it slip or unlock on me so I nthink they are just right.
EDIT: Here was what I had
Originally Posted by wtf_lol form email with aussie
For the Pinion gap, with the unit at rest it was less then 0. I had to spread the unit apart to even get the pinion shaft in. Once it was in, at rest it was pushed against the shaft, spread apart (so thrust washer was flat) I was roughly ~.010. The gauge I had was not as specific as I would have wanted it to be but it was enough to tell if I was within tolerance. For the Cam gear gap, I didn't make a note of what ti was at rest but it was tighter then the tolerance alowed, I remember doing the math and figuring out that at rest the TJ thrust washers would be to loose. I am surprised to hear that you where at .135 with the JK washers and spread apart, it seems that is about where I was with it at rest with the JK washers. I will have to find my notes but it seems I was at about roughly .155 with the JK washers and spread open.
looks like Aussie also had .135 on thier test fit. I think that is also about what mine was at rest