help with differential clunking after rebuild!
 

hey guys, I worked on my differential today ( replaced worn out clutch pack... ) 8.8 limitied slip rear end. 3.73 gears
well the locking bolt was broken and it took some persuasion powers to get it out, in hte process my helper tool slipped nicked the outside ring of the pinion gear.

now the car pulls great gear wise ( no one wheel peel) , but when rolling it is shaking a lot, is this the ring and pinnion or sokthing else causing a clunking sound when cruising and the shaking of the rear axle?


do i need to replace the ring an pinnion now or possible a bearing?

Any help appreciated.

1998 GT if it matters

Did you make sure that the diff fluid you used had friction modifier in? If not, did you add any?

Did you check your backlash after you tightened everything back up? My guess is that your backlash is way on the high side of things, say over .012 or higher. Hence the clunk clunk sound. DId you adequately tighten the pinion bolt up against the old crush sleeve? That is a hard one to do just by feel. The best way is to measure backlash before and after the rebuild.

used royal purple 75w90, and the 4oz motorcraft friction modifier included in the clutch pack kit ( the kit was from ford)


at first the car was grabbing with slow turns, but after about 3 slow circles in both directions it was gone.
Friction modifier or not, i dont think its relating to the spider gears. as the sound is not when turning.

the clunk is when going straight, even with the car lifted and the wheels are not touching the ground. The noise is definately on the coast, but i cannot tell if it is when driving as my car is to loud to tell

after looking all over the net, im convineced its the backlash myself. Monday is my next day to work on it, if going to drop some new gears in it since the current ring has a chip in it.