Right, nearly finished building my box/diff - Its (still!) on the bench.
Everytrhing was fine until I torqued up the speedo side (passenger's side on UK car) big hardy-spicer flange bolt to the specified torque (55 nm).
As I turn that flange, it becomes quite stiff at a certain point. Looking inside the box, this happens every revolution of the crownwheel and at the same point (i marked the teeth) when it meets the pinion gear.
The clutch/drivers side is also slightly (very tiny ammount) stiffer at this point but not really noticeable, and had I not investigated the passenger side, I don't think I would have noticed or worried about it.
Neither side show any resistance when the bolts are not torqued up.'
The facts:
Box is rebuilt and checked
The pinon is torqued to 207 Nm
The bushes on the output shaft and end covers have been replaced and proffesionally machined to the tollerances reccomended.
All diff internal parts replaced except output shafts and cross pins that looked OK. Everything here torqued to spec.
The diff felt nice and smooth before it went in.
Bearings are new
The diff is correctly shimmed
The end covers/diff rear-cover are correctly torqued with their gaskets
The half moon collets are in the flange (though these were slightly diffent thicknesses so have filed so that they are even) along with rubber seal.
Everything else moves smoothly.
The crown wheel and pinion are both used and not a matching pair, so my first thought is that it could be that?
I am trying to understand:
Why binding happens at a certain point
Why this happens on just one side
Why only when its torqued up.
Perhaps the parts will wear into eachother when driving it's actually all OK?
cheers, Tom
