Originally Posted by imprsme

What does your thrust bearing look like? You may have the "old" one. The old one has an opening on one side of the thrust and looks very thin. If this is the case then that is your problem.

You say you have carbide balls installed, also get the ceramic thrust bearings.

I too had to rebuild more than I wanted to, until I did the carbide/ceramics now I have been on the same build for almost 3 months and it is still BUTTER SMOOTH!

I am only using the 4 cone washers, but remember to TAKE YOUR TIME while tightening the diff the first time. Work the diff after every small turn of the screw.

Hope this helps!