here is what i did some time ago (i saw this on a german site an tought i can do this myself)

first of all



these are the parts needed to do the mod and some other stuff ( i explain later)
You can see the pins have a notch (like everybody has nowa days :wink: )
But on the end there hase been some material removed so it could fit in those tiny things on the left
these are made from stainless steel and the dimensions are 7 x 4 x 2 mm and there is a hole in them witch has a diameter of 2.2 mm
(for the US friends it is 0.27559 x 0.15748 x 0.07874 inch and the hole is 0.086614)

this is how it looks like





so first i did the shimming the diff methode (i am not going to explain all of this because sicj did a splendid how to on it so if you want to know how use the search please)
here is everything needed to do one diff



First i bought some shims that are 0.05 mm thick (0.001968 inch)
You can cut it with your siccors but for the hole well that is a different story
I used a smal drill bit in my dremel then put some plastic behind the shim and drilled, then when i got the hole i dremeld it until to proper size
Takes time



the shim has as porpuse that the gear doesn't eat his way into the plastic.

installing the crosspins



Sorry for the blurry pic
here is it at another angle



As you can see first you put the 2 gears then a shim (on both sides) then the "blocks"
Notice that the shims are rounded so that they stay smooth

Everything into place



Here is a better pics where you can see the shims



and then at least filled it with grease
i use Molycote BR 2 plus but that is up to your own taste hehe



and then you finisch it of like normally (i think most off us now how to do that don't we :wink: )

Well here is the update
I drove with these diffs about a year (about 3-4 gallon but i don't remember if this is quite correct ops: )
So it is winter time here right now and i decided to open the diffs just to see how messed up they where(and to change the bearings)
Remember i drove these things with a sts. 28 on there back :lol:
I wasn't gentle with them either
This is how the back side looked like



The bulkhead



So you see that i use the truck for what it is build for :P

The diff housing



The diff



As you guys can see the screws didn't back out
I used the longest machine screws that could get in there and before tighten them i used a bit off CA glue on the top

Inside the diff



The plastic cup after cleaning



The rest that was in the diff after cleaning



Well, i changed the bearings(they where real bad :P ) and put here back together with all the stuff that you see in the last pic
Every gear was still in perfect condition and the plastic housing had no play
I know there must be more testing involved before you can really say that this is the perfect diff

Hope you you guys liked it

Bye

Noël