G....I think I should come over and have a look. You free one night next week ?
Im going to be starting to put together the spare car tonight. The ball diff is already in the used car and I have a GD for the unused one. I plan on getting the BD out though to clean it up and rebuild.
There are a couple of things I noticed with the BD.
The thrust race cage looks a tad flimsy. Check it over well and make sure each of the balls is able to move freely. I had the issue when I ran for Serpent UK and the S410 where the cage couldnt take it and would fold onto the balls and clamp them, this lead to the diff clamping up and then it would blow the cage to pieces. Check this as a priority.
I would soak the diff outdrive where the thrust goes in in alot of motor cleaner. Leave it for a good hour, then give it a really good spray though. It could be some gunk is in the slot of the E clip and this is causing binding possibly under load, not something you can simulate in your hand.
Get right into it best you can to clean it up.
Check on all the thrust plates and diff plates for any over wear. Are all the plates flat ? Check the thrust ones on a setup board or across a metal rule. I would also sand the diff plates to flatten them off again. Use 1000W&D with some motor cleaner to do that mate.
Asside from that I know you know your way round a car, so I know you will have though of alot. Lets see what we can achieve from the above, if not perhaps a cup of tea next week and some pearing into a BD !
(Plus I havent seen little'un in ages)
JP
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