If your having problems replace the screw and nut. It sounds like another rebuild is needed, wash away all the grease with either brake cleaner or activator, and use a good clear silicone grease such as associated for the diff, and black grease for the thrust.
Sand any grooves out of the plates with very fine wet and dry, the place a little clear grease on the outdrives and put the plates on. Smear the plates with some more of the clear grease, you want a nice thin covering all the way round the plates.
Stand the male out drive up, and place the diff gear on the outdrive/plate. Put balls in, and place the female out drive on top.
Put the thrust race on the screw greasing the thrust well, with black grease.
Carefully lift the diff up and insert the screw and start to tighten. Once the screw starts to grip, stop tightening and rotate the outdrives, continue to tighten until the diff is tight.
You can tell when then diff is tight by putting two allen key through the outdrives and trying to rotate the diff gear. If it rotates then you need to tighten the diff a little more.
Don't forget to compress the spring if you've not already done so.
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