I don't recall if the 2003 have the diff lock still inside the TC or not, but if they do, I recommend you include in your order the mechanism Ashcroft usually has to connect to it.
That’s really common a D2s. I think it’s just poor quality metal in the carrier. This can be avoided if you install a locker or LSDThink I found the problem:
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I ordered a new third member like y’all recommended and pulled the existing one. It didn’t take long to see what was wrong. That pin is as loose as can be and the crown wheel was forcing it through its housing. What could cause that pin to slip down like that initially?
Thanks for all the advice!