Hiya, i did have a similar problem with one of my diffs when i was rebuilding then with the new outdrives before the petit and found in the end that it was down to the clip holding in the thrust race. What had happened was that when i'd taken the clip out it had cent slightly so that when it got put back together, although all looked good once i put it back in the car and tested it it came out of the locating groove and caused the diff to loosen off. I stretched the clip back out a bit and get presto it was find.
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