Best suggestion ever! <img src="/forums/images/graemlins/kewl.gif" alt="" />

I didn't start having an issue with the half shaft popping out until the first time I blew one up on both of my gen 1's. Once I pulled everything apart to replace it and reassembled it, the problem started. The first gen 1 actually ended up being a really easy fix in the end. I replaced with an OE clip first and didn't work. So I went to a local hardware store and just found one a tad bit thicker than stock. Never had this problem again. The 2nd gen 1 (current) I have actually yet to solve this issue ever since I blew up the first half shaft. I think part of this reason is becasue of how chewed up the inner part of the carrier has gotten from dislodging twisted splines that are seized up inside (not fun).

In my opinion. Buy a thicker C-clip, If you have to do a little bit of filing to make a good fit then do so. No sense in machining anything or customizing anything until all of the easier possible solutions have been tried. <img src="/forums/images/graemlins/cheers.gif" alt="" />