No mate, no probs front or rear
, check back through the book make sure you have got it all built right, I know it sounds silly but your the 1st I've heard of with this problem, I know what you are saying,I had that problem with the mad monkey few years ago but never had it with any other car,
Errm things I can think of off the top of my head:
Did you crush spring before building diff
Thrust race built correctly
Is the nut holder all the way home and you are not actually tightening diff(long shot that
)
Are you using the correct bolt
are all the diff balls and thrust race balls seated properly as if not they could be causing the diff to be wider than it should be by a few mm, If you had a fiddle putting the thrust race in and it fell apart so you had another go, make sure you have the correct number off balls and that one hasn't crept into the drive cup.
I have just had another look at mine and I have loads of clearance throughout out full suspension travel, so you must have a fairly obvious problem somewhere…front and rear