Been a while... New babies will do that to ya though.
In the mean time I've been trying to get the D30 done. And I'm having a heck of a time with the pinion and the yoke. There is a considerable amount of interference and takes incredible force to get the yoke down onto the pinion.
My Revolution rep initially stated "I don't think this is normal". Now Revolution is saying these gears are in spec and to take it to a shop. I'm still adamant somethings not right.
In the pics below you can see how the splines on the new pinion leave a bit of a gap with the yoke splines vs the old stock gears. I bought a new pinion thinking that was the issue. Same problem.
As far down as the yoke will go with a few whacks from a dead blow hammer.
The same yoke with the old pinion, no hits required.
You can see the gap between the splines vs the old pinion below.
Anyone have any insight? My Revolution rep is going to speak to his supervisor about a replacement. We'll see.