Hi matey,
Did you compress the spring a few times in pliers to 'soften' when building from new?
Sounds like you are tightening diff up too much, or maybe too much too soon before it's bedded in.
The thrust washers do wear with use and don't last forever but will see you through a fair few meetings before needing replacing if the diff is maintained and set up well.
Breaking any ball diff in after rebuild is crucial to it performing well and lasting well... i would never build a diff, tighten it up and then try and race on it, always set it so it's just nipped up or slightly slipping, do a short low speed run on a section of track between heats if possible at a meeting, maybe a couple of figure 8's and then it's bound to be settled in so can be tightened up to a race setting.
The tighter you run a ball diff the shorter it's life will be because of the pressure on components, increased heat and generally more friction... i run my diffs tight but they get rebuilt/regreased regular (every couple of meetings) and plates maintained or replaced when they are worn.
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Mr F.Chimp
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