Regarding ball diffs I have found that they might start off smooth and tight when first assembled, with or without extra cone washers, 1150 bearing etc. However after a few runs they becomenotchy, not sure why this is but it has happened to most of mine, even when using lots of anti-wear grease. Perhaps the balls get flat spots when they tensioned down. This is using only the balls provided in the ball diffs.

I am trialling a tight gear diff for now. This appears to remain smooth after many runs.

Regards,

Calvin.