Originally Posted by
jakeg1999
I am having the same problem and I am pulling my hair out over it. I have rebuilt the darn diff 5 times in the last 2 hours, putting shims in all locations. I have already stripped two screws that hold the diff case together and am getting very frustrated. The shims don't seem to work at all. The diff is smooth as is, but as soon as I put the screws into the box to bolt it to the rear end, it starts to get really rough. It's the two box halves pressing together that makes it rough....Any ideas? Is the HD box any better? I am getting very frustrated, and the worst part is the darn screws stripping, as I have to spend 20 minutes drilling them out.....
If you are using the aluminum bearing inserts, you need to sand the ends that face the bearing slightly. They will push against the bearing when you put them in the case and tighten the screws, making if feel notchy when it's together. Otherwise, it feels smooth in your hands when out of the case.