ORIGINAL: Da Smak
but even with the washer out it shouldn't chew through the case as the back of the gears is smooth. I take it you mean an e-clip off of a suspension hinge pin, but even then I don't see how that could cause that damage. IMO you either fitted the wrong gears in the diff, never lubed it or filled it too much. Either way though, I think that case has had it.
Nope. All were fresh rebuilt and doaners from another Parts truck. Yes it was a rear suspension Outer Hinge pin that was sliding out and hitting the rim in the turns. It has to be what was causeing it. As it has not done it since we fixed the hinge pin.