I just rebuilt my front diff and found the input shaft had a tiny bit of play which wasn't there before. Tried shortening the shaft more, but it didn't help. What I found was I had to length the flat spot a bit using a dremel. After that, I was able to clamp the input shaft assemebly tightly on the bearings. Actually, I got it so tight the bearings felt notchy so I re-did it with a bit less pressure.
I originally only lengthened the flat spot on my rear diff because the front seemed ok. But since I've had to do both my diffs now, I'd say it seems the flat spot cut on the shaft from factory is just too short and so it doesn't allow enough adjustment to clamp the bearings tight enough to get rid of the play.
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