Hi Danny
I had this with my sons Schumacher SX2 diffs. I found that if I nipped it up too tight initially it was crunchy and did not smooth out.
I heard that breaking in the diffs first was a good idea but most methods seemed a bit of a faff, running the car on the bench or using a dedicated diff break in machine.
What I did to fix then was to resand the plates - incidently they need to grip the balls so not too polished, I used 800 grit paper - rebuilt the diffs with fresh grease and barely tightened and then ran the diff in an electric drill by gripping the outdrive in the chuck (gently) and holding the gear in my hand. I then ran the drill slowly in both directions, tightened the diff a bit more and then repeated 3 or 4 times until the diff was tight enough and smooth as butter. I have not had to rebuild the diffs for 3 months now and have done the same with my B44.1 diffs as well now and have not needed to change them in the same period.
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