That's rough luck Adey.
I have always found Team-C plastic parts to be of a very high standard so perhaps Kev will be able to sort something out. It sounds like the early production run on these parts is a bit out of tolerance.
Is the chassis itself ok? I'm expecting mine in a day or so.
Not sure about the diff. Is it stiff as in lumpy or just plain stiff? Again, my Team-C geared diff is a dream so I can't say why you might be having a problem. The only problem that I have had stemmed from putting really thick oil in. On a high grip track it wore notches in the out-drives in a single meeting! All better now.