I had EXACTLY the same diff problem.
You can't get your diff right because the clip is buggered, as you tighten the diff the clip is moving, it's not being retained in the groove as it should.
You could try the 'spread' tip that Adam posted, i.e trying to open the clip back up once it's in position.
IMO the clip is a bit crap, mine was replaced with a Schumacher clip and the diff is like night and day now, I think the Schumacher clips must be stronger ?
Good luck.
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