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07.05.2011, 12:16 PM
Swapping the gear positions inside shouldn't make much difference - Mugen gears are nearly identical and could very likely be substituted internally and I would be interested in the result, actually.
The "notchiness" could be from the internal gears being slightly too tight or too loose. It doesn't take much either way to create a little notchy feel. Loose is bad and will ultimately lead to stripped internal gears. Tight will usually break in(ideally, a new diff has a slight nothiness before being run). Is there any "play" in the outdrives when you try to diff it by hand? This would typically indicate a slightly loose internal mesh. You described the diff a tight and notchy, though - does it get caught anywhere when manually diffing it, or is there simply a "less than perfectly smooth' feel when diffing it manually?
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