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Originally Posted by Serum
Check the bottom of the main gear for burrs/deforming.
the M2 hole is made M3, and the hole is countersunk again, which takes a lot of pressure because of the hardness of the steel. This might have deformed the material slightly causing it to bind at every turn. (in other words, the gear isn't flush with the case) perhaps there are burs on the cup itself?
or is the problem inner gear related? In this case; check if the pin that holds the two floating gears is loose in the case, with some of the diffs you need to dremel a round spot to the end of the small shaft that holds these two floating gears.
You did cross-tightened the screws?
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I have dissassembled the cups many times and tried cleaning the surface where the cup meets the main gear. Burs in the cup are all gone (there was even some in the screw holes). This was on both diffs.
The Inner gears have slight play, so I ruled that out. i already grinded the pins so they slide in snug and sit all the way in.
I did attempt to cross tighten the diffs.... tried different ways and it did improve it quite abit... but there's still that rough spot that bothers me.