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!