Quote Originally Posted by Sandgroper View Post
Only thing i have touched on the front diff is changing the pinion flange to fit td42 driveshaft... so maybe i havent tightened the pinion nut enough... or too much?
Did you set the pinion bearing preload according to the factory specs using a proper tool(inch pound torque gauge), a makeshift tool(handing digital weighing scale) or at least set to the previous preload by "feeling"? IMHO, it's way too critical to set it by feeling, unless you have bit of experience with diff rebuilding.