Originally posted by Hebiki
there's about a billion different ways to solve it according to the thread, is there a solution that works better than most? please help!
Shim the diff with 10mm shims, so that its just got enough play to run smoothly but if you put 1 more it starts 'grinding'. Different gearboxes, different # of shims required.
Then screw the cover back on, but don't overtighten the screws - barely snug tight will do. Change the screws to longer machine-threads too.
If you have the $$$ to spare, Square alloy gearbox is good.
Tech 3-piece shaft? Consensus is still out on that, but its been pretty good to me. But I think the original 1-piece is lighter and runs smoother.
And methink it helps to have Murphy on your side too. I only seem to strip a gear whenever I don't have any spares left.
But when I have huge stocks and carry a few in the toolbox, the gears come back perfect. Ever since I stocked up... and did most of the above... haven't chewed a gear again.