Slipper issues

[_dV]

Issues during assembly:-
1) Slipper pads didn't fit and they required a fair bit of filing
2) Burs around the outside of the thrust washers ..more filing
3) Was very difficult to get the pin in the spur gear side diff cup, there just wasn't adequate room. Apparently you can do this before screwing that side cover on but that isn't the order that the manual tells you to do it in and i assumed the manual was in that order for a reason.

After assembly i've had the diff sitting around on my workbench. Hasn't been used yet but it has been leaking a fair bit (100K fluid). Finally got around to taking the diff side cover off to see if i can fix. Cover was on nice and tight and gasket fitted correctly. On close examination i could see 3 things that might be causing the leakage. I can feel very slight burs in the screw holes on diff side cover plate, the screw hole threads in the diff casing have raised up slightly on the surface under tightening (they weren't countersunk to prevent this); and finally the outside edge of the diff casing mating surface i can easily see that its not flat\true where the adjustment ring thread ends.

So i'm thinking that i'm not too keen on trying to file those surfaces to ensure they are flat. Not sure how to proceed atm... Could be that none of those thing are susbstantial enought to affect the fit and i'm missing something so might just re-orient the cover and try again. Don't have much hope for this approach though.