G80 Locking Diff-clunking on engagement, lots of driveshaft play.

[Rushin]

1992 Volvo 240

I have been fighting various diff-related issues owing to the PO not shimming diff bearings correctly, botching the install, etc. The previous owner did an axle or diff swap and put a G80 locker in, and I've had to fix a lot of their mistakes.

Anyways, on takeoff, I'm getting a pretty big clunk when I come off the clutch and into first gear, and after shifting into another gear. It is tied with their being load on the driveshaft, when the driveshaft is unloaded, it spins freely, but once torque is applied, *clunk*. I pulled the cover for the fifth time to make sure I didn't screw anything up, and my backlash is good, the diff doesn't shift, but the ring gear rotates some ways before the axles engage. It looks like some internal guts are blown out. Is there a way to correct this? Or at least a way to bypass it until I can get a new diff/rear end in there? I have an autocross event on Sunday that I'm really trying not to miss.The driveshaft in neutral has about a 1/8 turn before the axles engage, even though the pinion engages the ring gear basically immediately, and there is no whining, shuddering, etc. Link to video below.

 

[HiSPL]

 

[Rushin]

That unfortunately was my thought too lol. Do I just weld the pawl or do I have to pull it out?

 

[HiSPL]

Most people just weld the pawl so it never disengages, but I’m not super positive that is what’s wrong with your diff.

Most of the time if a G80 blows out it just doesn’t lock anymore.

 

[Rushin]

Most people just weld the pawl so it never disengages, but I’m not super positive that is what’s wrong with your diff.

Most of the time if a G80 blows out it just doesn’t lock anymore.

I just have a ton of free play until it does lock. I'd prefer it to not lock, haha. I'm going to mess with the pawl a bit tomorrow to see if I can have it open or have it engage a little nicer.

 

[VB242]

Have you checked the U- joints and center bearing?

 

[OVERDRIVE]

If there was excessive ring gear backlash you'd probably be hearing it "howl" not clunk.

 

[Rushin]

Have you checked the U- joints and center bearing?

I replaced those a few weeks ago, all good there. With the driveshaft d/ced it still clunked. Turns out there was some lateral play in the diff. Under load you could see it move, but turning by hand wouldn't show much.