Looks exactly like mine, before and after assembly including same amount of play with the brake discs. Initially I also thought the same as you, that there was too much play / distance between the inboard and outboard brake discs after assembly and releasing the spring tension - but my ball-bearings remained in place and do not become trapped so i wasn't worried.
Either way I don't think using the old brake hub (spacer with no recess) together with the old / shorter spring would help.
I am planning to fit the brake shaft into the housing tomorrow and will let you know if that "play" is taken up when the shaft is fitted into the housing.
If you're somewhere around the Bassendean area, give me a ring and stop by. Mobile zero 408 915 six eight zero.
G'day Kristoffa, I had the same two piece brake shaft and although I didn't have the same problem above, I noticed that once I dropped the rectangular retaining plate into the brake shaft groove during final assembly, it took away most of the free play between the brake discs.
If faced with the above problem (bearings fall out when releasing the clamp) then I think you could bend up some flat bar to hold the discs together until after assembly of the shaft into the housing. The spring force is not that great and it's easily compressed by hand.
The other alternative is to build the brake assembly after fitting the brake shaft in the housing.
Sorry guys, been crazy busy with work.
Put it all back together after being told my brake is fine and from what I can see, it all appears to work.
Just need to get my winch bar made up, add some Dyneema and wire it all up.
Cost break down for the rebuild.
Original purchase price - $50
Brake rebuild kit - $160
Lower seal kit - $60
Brake shaft bearing - $25
Paint - $10
Oil and gasket goo - already had
New solenoid pack - $40 (1 x carton of beer)
Sticker kit - Free from WARN