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J30 VLSD? Yeah it is. Sounds like the VLSD unit got clocked slightly relative to the splines on the spider gears while you had it apart to install the shim. You should be able to slide the side shaft in until it's mated with the spider gear, then turn it slightly until it can slide into the viscous coupler. You may need to insert the opposite side shaft in as far as it'll go and wiggle them both.
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