Out of interest, incase anyone was following this in the future, i did manage to get adjustment on the diff in the end without changing the spings washers, thrust race or the circlip etc, however it is a very fine difference between slipping, correct adjustement, and locked... So based on this I am pretty much of the opinion that it is due the spring washers being flattened, as this would therefore reduce the spring load that they apply to the friction 18mm washers, and inturn onto the balls when applying the standard recommendation of adjustment, whilst also increasing the sensitivity of the adjustment itself. Certainly is it very much less than a 90 degree turn of the thread which on a 1mm thread pitch would equate to 0.25mm compression difference from fully clamped/loaded.
So the cure has to be new washers to get the adjustment back, by my logic...
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