This exactly the problem! Mark is going to machine shop and have the correct size made tomorrow.
Post:
Dana 35C and the Detroit TrueTrac
I was in the process of replacing my worn out Trac-loc with a Detroit Truetrac and found an anomaly I thought you all should be aware of. Since the Dana 35C is a C clip style axle the axle end play is controlled by the cross pin. The Detriot TT uses a button to do the same thing since it uses a helical gear driven diff. Once I got the backlash set I slid in the new axles and found .062" between the button and axles. After a phone call to Eaton I found that Dana made these diffs/axles with two different cross pins, one that measures .687" and one that measures .718". I ran out to the garage, measured the cross pin out of the old axle and sure enough, it was .718". I asked Eaton if they could just send me the correct button and the response was "No, we don't make one." Stellar customer service if I do say so myself.
Anyway, I just brought the supplied button in to a local machine shop and had them make me one at .718" out of some 4140 stock and all is good, but that was an unexpected expense and it was not cheap.