Hmmm, odd one... Definately built correctly? Is it a new or second hand car? I would advise ceramic diff balls as a start...
You dont need alot of grease in the diff, i usually just put a small blob in each hole of the diff gear then a smidge on the diff rings, nowhere else...
With it only being noisey when the pinion is meshed i would guess maybe the pinion or spur gear arent right, try a different spur/ pinion and see if theres a difference?
Hope that helps
Tom
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