Hey Kiku, the pics help... Everyone else, whats exactly happening to the blocker rings? Is the friction material wearing out or are you grinding off dog teeth? Biggest suggestion I do have concerning the blocker rings is(even though it sounds stupid and everyone already knows) Push the clutch to the floor when shifting. Another question I have... How often have these broke on stock engines? As for the diff. there have been instances on high mileage vehicles where the roll pin comes out. I know for a fact that they (engineers) are working on a permanent fix. Though I doubt that involves welding. Reason being, heat distortion and shimming of the side gears during manufacturing. I know we are working on a program right now that uses the side gears from the T350 and the shaft is held on by a C-clip. We are in the testing phase and I'll let you guys know how that comes out.

Its a little hard to get my hands on the actual engineers since they are in Syracuse, NY and I am here in Troy, MI... But I'm working on it. I have a couple of emails out already. Man they're gonna hate me in about a month.