Cougar Diff . . . . .Again!!

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Hi Lads,

I did a search and had a read of other posts about the diff & have looked at various online vids about rebuilding.

This is what I've done:

1. Sanded diff rings using 600 paper + some WD40, kept sanding using one of the outdrives until I got a grey surface all around
2. Used new diff balls
3. Used new diff screw and conical washers + new circlip
4. Used black grease on the thrust washer
5. Used diff grease on the balls & diff rings
6. Tightened up diff fully tight & backed off 90 degrees

Diff still feels very 'gritty'?

I have another diff not built by me & it feels a lot smoother, I'm just trying to figure out what I'm not doing right?

With the circlip, I've spread the clip so there is a 4.5mm gap and did my best to get it positioned without squeezing it too much but it still feels loose in it's grove. I'm also aware there are two sides to the clip and have it orientated correctly.

So, Schumacher guru's what am I doing wrong? Why is my diff still gritty