JP, very carefully take the minute bit of flashing off the back of the diff pinion gear. It sorted mine and they are super smooth!

do you mean the small gear on the drive shaft that goes into the gear box?

He does indeed

not helped mine so far, if I loosen the gear box its fine.
will have another try while its in parts!

Make a bit of a gasket out of cheese to go between the diff housings.
It needs to be proper cheese, not that crap you get in burgers.
Please pm Stu if you require more help with cheese.

J

Mines tight too, but ive read alot of posts on the Yank forums saying it beds in after a few runs.
Prefer tight to loose......transmissions of course ;)

I prefer it too but in more than just transmissions ;) :D

Just thought I'd update everyone on the notchy gear issue.

Ran a couple of packs through my car and the gears remained as notchy as ever. In fact, during my runs my deans plugs were getting really hot... in one case even the solder joint came undone. Car was not overgeared by any means so my guess was that the tight gears were constantly adding load for the motor to work out.

Stripping down the car I found that everytime the gearbox was closed up the gears would get tight... even when I removed all the shims to loosen up the gear mesh.

On close inspection I realized that the gears were shimmed correctly from the factory. The tightness wasn't caused by a tight mesh. Rather, it was the outer edges of the bevels on ring and pinion gear that were causing the notchiness. (the next time you open up your gearboxes take a look and you'll see what I mean) :)

So I carefully took some material off the outer edge of the gears. Particularly on the ring gear I basically gave it a slight "bevel" on the outer edge. Assembled the gearbox back together and that fixed my notchy problem. Same shimming as per instructions and everything was smooth.

Mine seemed fine when i tried it but if the problem does arise on my transmission then i'll file abit of it off like you say, already had to do this to one of the new b4 idler gears so should be if i have to do it for my b44 too :D