Have a friend that keeps snapping his pinion pin inside the carrier housing?
This is number two (complete) diff I have put in. Had a local 4x4 shop tell me to spot weld the pin on each end at the snap ring and that would stop the pin from working it self out. Don't think this a good idea. Does any one else have pinion pin breaking issues. RDF

 

What's he doing when it breaks?

 

Yes, I have seen the pin snap in half leading to catastrophic failure of the front diff on an '03 disco, We replaced the diff with a 4 spider diff, only to find that the ABS/TC/HDC was not working. a large slip of either front wheel on sand/mud/water and the consequent "hammering" of the drive train once the slipping wheel grabs again was the most likely culprit.