Today's effort were to rebuild the center diff with the metal case and switch it up to open config. Initially, I bought the OEM spacer kit to accomplish this task and stumbled on a thread mentioning a better way. So, instead of the OEM open diff shim kit, I used two of the LSD plates without ear to bolster the pin crosses of the sun gears on either end. I used shims to gain the thickness I needed and threw in another .005" accumulatively to ensure a good tight fit.
I also replaced the undersized OEM cross pins with a set from RamJam Racing. The slightly thicker pins further eliminate some of the slop the OEM pins allowed. I topped everything off with 500k diff fluid.
I also threw in the 16 tooth pinion while I was in there.
I have a little bit of a head scratcher though... So, with the center diff top off, I can grab the wheel hexes and turn the motor over by twisting them pretty easily. As soon as I install the center diff top, it becomes significantly harder to turn the wheel hexes by hand. I can't figure it out. I can see light between the center diff housing and the diff on both sides with the top on. The new metal cases are very close to touching the center diff mount, but there is a sliver of light, indicating clearance, at all times in the center diff's rotation. It's not touching anywhere but the bearings. Yet, it becomes harder to turn with the top installed. It's still movable by hand, just more difficult. I can't find anything pinching or binding or touching that shouldn't be. I think I'll probably just run it and hope it "breaks in."
I've got two more diffs to rebuild, if anyone needs some of the LSD shims w/ears, I know a guy!