I also ran into this problem. Once I figured it out its ok, but at first it was very tough. I hope with some use it'll be easier to take this diff apart. I regrease my outdrive regularly and thats going to be tough with this diff.
When you build them, if they lock up real bad, thats because the side gear and the bevel ring are binding up and not installed down all the way. The guts are stuck apart and too thick, and the diff locks up as the screws are tightened.
Even worse is that after tightening those screws, and realizing it, it's too late. The pressure from the screws pressed the side gear and crooked bevel ring together and they are siezed and you will not be able to remove them to fix the problem.
A way to be sure that that is the problem. Remove the 4 spider gears and cross pins. Put the diff together with very little fluid and no spidergears or cross pins. Is it still bound up?
If it is, the easy solution to knock the side gear and bevel ring together is to set the diff outdrive down ,without the spiders and cross pins installed, on top of a block of steel or vice. Tap the on the other outdrive gently with a 14once steell ball peen hammer. That should reseat the bevel ring and side gears and the diff should free up.
Keep in mind that if you hold the diff carrier and spin one of the outdrives it's supposed to bind up some. I'm talking about holding one outdrive and not being able to spin the other.
I dont know why Xray choose to make the bevel ring and side gear two pieces. Maybe they are a different matrerial or something. They have different coatings.
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