So i have an 09 jk x dana 30 in the front and dana 44 in rear i just
bought complete change over set up from randys to change from 321 to 456s
the rear went great when it came to the front i changed carrier for the new ring gear
as well as spiders but when it came to the pinion i found that the pinion
flange where it slides down the shaft on the new pinion. where it tapers is
causing the flange to stop early and is about an 1/8 inch to high and wont even come close to crushing. this has turned my one day gear install into a mess im a chevy tech at a reputable dealership so this isnt my first gear install in a rig but it
is my first jk set up. i called randys and they want me to send them pics of issue.
the ring and pinion are usa standard i have done my research and gears are gears from what most of the forums have said and im not concrend to much about noise. i was just wondering if any one has had this issue. in the pic the pinion on the left is the new one you can see wher the oil slinger stops in comparison to the pinion flange of the original pinion. i will be sending randys pics on monday i hope they can fix issue im supposed to lift and tire next weekend ? has anyone else had this happen randys is being cool and hopes to have solution

 

so they said i needed to grind down pinion shaft a bit as they have ran into this
befor bruce was great to deal with and sent new seals and nuts after triming down shaft a bit slid right together THANKS RANDYS (bruce) any how gears are in and jhust finished lift so

 

I have dug this thread from the grave. Just wanted to tell you, I am having the same issue right now but my Jeep is at a 4wd shop. The installer called me and advised this exact info you posted. The fix, will be just putting in a G2 4.56 ring and pinion in the front.

Just wanted to let anyone purchasing gears know of this issue, if you buy USA Standard for a JK D30 front.

 

It doesn't seem like you could grind on a pinion shaft and that it would be balanced spinning at 6,000+ rpm. Shady.