I have an aussie in my D30, it's a few years old but has very few miles on it. Last year I had a shaft break at the splines and destroy the carrier. I just got it back up and running but now the aussie is terrible. It was quiet as can be before, but now it's pretty loud, doesn't release as well as it used to and the teeth jump under medium load. Hard load it will lock up. All the teeth looked brand new to me when I installed it this time... I did also just install some ten factory shafts, which were a pretty tight fit on the splines. I had to lightly tap them into place. I can see that causing problems for releasing, but not locking. All gaps are within spec, carrier is brand new, cross pin is in good shape and I have thrust washers installed on both sides. I installed it the exact same way/ orientation that it came out. Any ideas? If it's the shaft splines, what the heck am I going to do about that?