Originally Posted by saline
Thanks for the quick reply! I'm under a time crunch right now, and a bit worried since I have uneven tire wear on the inboard side of my rear tire.
Did you have to specify different seals/bearings due to the larger diameter shaft?
Nope, no seals involved unless you pull the hubs off which isn't necessary if the donor axle is in good shape. The bearings are on the carrier and in the hubs, so the shafts don't interface them at all. There is a metal gasket on the interface between the axle-shaft and the hub for each side, but if it is in poor shape I believe a re-coating with gasket spray, or thin RTV would work in place (I had a hard time finding anyone selling them, and ended up not needing it anyway).
The axle we purchased had the same 4.1 ratio, so I re-used the gear-set from that axle so that I would not have to mess with setting the pinion depth/pre-load and all of that.
For shimming the carrier I found http://broncograveyard.com
to offer the best price with shipping for getting a selection of shims and some spare hub-bearings and seals that I didn't end up needing, but may be nice to have on hand. I have given up on local shops, with NAPA being 2-3x the price of anyone else, and the other chains being staffed by folks that only know how to run a database, not anything real about working on vehicles.