Zero lash (or in your case what sounds like negitive lash) really isn't a
good idea. The ring gear will get hot in that area, expand, then get ever
tighter/hotter.
Can you get a dial indicator against the back of the ring gear and diff
carrier? This would give a good indication if the gear has uneven wear, bent
carrier or unseated ring gear.
If the ring gear was removed there is a possibility it is not fully seated on
the carrier. If the carrier ( differential ) bearings were changed, there is
a chance they are not fully seated and allowing it to wobble.
I don't know what the typical runout would be for a TR diff, this amount or
runout may be normal. In that case I'd use the lower spec for the tight area
and live with the larger lash on the high end.
The pinion nut was probably tightened properly, if it was loose I'd suspect
the splines to be worn and lots of brown rust on the shaft from fretting. (
Fretting is when two steel surfaces slowly work against each other, small
particles of steel shavings are generated. These particles rust quickly
leaving a tell tale sign of brown rust.)
When a pinion is under driving load, it if pushed forward so a loose nut
isn't a problem.
During coast, the pinion is pulled to the rear of the car. In this
situation the lash can decrease, but due to shorter load times this may or
may not cause wear.
There is probably more, but that is all the time I have now.
Harold
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