Quote:
Originally Posted by adey
Another thought is to check the thrust bearing in the diff to make sure the circlip isn't slipping out of place when the diff is tightened up
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He's running a gear diff so that isn't the issue.
The only thing that I can think of is the gearbox moulding is slightly out or the screws that hold the two halves together are being over tightened slightly. Back them off a little and see if that makes a difference.
If that doesn't work then I'd suggest sending the case back to TD Customer Support (Good luck with getting a response, this is why I won't touch TD again). Seriously it sounds like a dud gearbox tbh.