[bobbader]

Steve,

You didn't mention if the roller track housings and camshafts are new repos or original parts. I have done many brake system rebuilds and have never has an issue with the size of new dust rings or the way they spring apart at their mating ends. (Note that the front brake rings are thicker than those for the rear brakes. That's number one.) If you are using new roller track housings and camshafts, there may be an issue in that the large "ball" end of the camshaft may not bottom out into the roller track housing as much as in an original housing. This will cause a binding problem if the dust ring is inserted or the inability to even insert the pin as you indicate. If this is the case, PM me and we'll talk further.

Bob Bader