Ok well I rebuilt the Diff again. this time I made it as tight as I could get the output shafts without them biding. I left the small washer on the outside and installed 2 large washers on the inside of each side behind the sun gear. I will post pics soon. to sho what happened. I called AE today and they are sending out somemore washers as I type this. I recomend toeveryone build the diff tight and order a diff rebuild kit I will need to replace the seal and "O"rings next time I take it apart.