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Dear 94 945T,
Hope you're well. Should I presume that your car has a turbo-euipped engine? If so, the transmission (Aisin-Warner 71), does not have a locking torque converter. Cars with non-turbo engines are equipped with a locking torque converter. That unit unlocks at about 48-50 miles/hour. There is a brief noise/thump, when the torque converter unlocks.
How many miles on this car? Has it been driven extensively, while low on differential oil?
I'm puzzled by your reference to servicing the differential "each 50K miles". So far as I know, the only service to be done to a differential is to change the lube oil. Unlike engine oil or automatic transmission fluid - which should be changed at fixed intervals - there is no set interval for changing differential oil.
Differential oil need not be changed so often as 50K miles, unless a car lives in hilly terrain and/or is used heavily for towing, or if rear axle and/or differential seals are failing, allowing oil to seep-out. In the latter event, the diff oil should be "topped-up".
If the problem truly is the differential carrier, I'd suggest trying to find a good used differential and rear axle unit. Rebuilding a differential is a major job. It is likely to be far more costly - in time and parts - than is sourcing a replacement diff/axle unit from a salvage yard. If you find such, simply replace the diff oil and install the unit.
I wonder if the driveshaft support carrier and its bearing are the source of the noise that you report. You might want to inspect them, and see if there's excessive play (looseness).
Hope this helps.
Yours faithfully,
Spook
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