Hey guys i was doing a rebuild on my MBX6T and when i pulled the diffs out i found that the front diff pinion, whilst running, was moving into the plastic diff cup/housing and chewing it out. How do i stop this from happening and what causes it.
It might have something to do with the drive cup (or yoke) at the other end of the pinion. That drive cup needs to be positioned as close to the diff casing as possible to reduce slop (the pinion sliding in and out).
If that doesn't help then I'll take another guess and say the bearings around the outdrives might be sloppy.
I agree with panda, if there is any play the pinion will "walk" into the spur, especially with spiral cut gears. If your drive cup or CVD can't secure close enough to the diff case to remove all play you will need to shim it.