Hi all , sorry for long break, I've been trying to log on but kept getting errors, plus broke my thumb which didn't help with the rebuild.
I'm terrible at taking pictures, I only remember after I've finished so sorry for the lack of progress.
Found a half shaft bearing collar tack weld in the diff housing so expect that was the main cause of the metal swarf. As mentioned previously I think the halfshaft bearing collar became loose on the shaft after Comb and was causing the noise.
Anyway, all done, preload of 3.4kg on the pinion flange with oil seal and 3.6kg with the diff installed so spot on.
Spread of 0.2 -0.22 on the carriers. Managed to get backlash set to 0.013-0.014 on my DTI so bang on as spec states 0.012-0.017mm
Meshing of gears looking perfect as well so pinion depth all good too.
Took a lot of time to get the crush washer to the correct size, many small adjustments and all done by hand with some wet and dry with a little axel oil lol. Time consuming but totally worth it. Actually enjoyed the whole process
Currently done around 50 miles, no whine at all from the diff, used to be soooo noisey, especially on coast.
Another 50 miles and I'll change the diff oil.
New 4.7 cwp makes one hell of a difference, flies through the gears now and noticeably quicker. Top speed at redline in 6th should be 145mph is which is morenthan enough for the tracks I will be going to....was gear for 185mph with the 4.1cwp. So taken 40mph of the top end, no longer a cruiser, its a proper rocket now
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