When all was said and done, did you have a tiny bit of end play in each axle?
One time I set one up without adequate end play and so the axles were pressed against the center spacer too tight. That made for a noisy diff. Then the first time one wheel spun at a higher speed than the other wheel, the inner ends of the axles welded themselves to the spacer. The spacer had to be cut in half with a torch in order to pull the axles out.
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Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)
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