Funny noise/clunk after STI swap

[malibud]

So i did the sti swap everything is great except for 1st gear. When I let out the clutch (especially if it slow) I get a clunk and a funny grinding noise ? Everything is tight but the diff kind floats there anyway . Is everything OK ? I did have to use a press to get in one of the shafts and was a bit worried there. I was going to drive a bit more and change the oil to look for metal shavings . Any advice is welcomed.

[Mark Maras]

A couple of questions; Are there any other symptoms, Shifting, high speed vibrations, noise in any other gear? What shaft did you have to press in? Describe the diff. float.

[John Coffey]

You should never, ever have to use a press to install one of the side shafts.

[malibud]

I am sorry did not mean float . just clunk from take off like the jostle from the drive shaft moves it then clunk it quickly goes it way . no other problems at high speed . I used a press because it would not go in with sledge hammer and 2x4. Dude a wolf creek thought it might be ok .

[Zed Head]

johnc knows more but is probably working... Ideally, the circlip would be the only resistance to the shaft fitting in its splined hole. If youhad to use a press then you have no idea if it was inserted to the correct depth (circlip in both grooves) or too far (rubbing on the dust seal and housing) or not far enough (binding the half-shaft). If it was mine, I would pull the axle back out, remove the circlip, and make sure the axle slides in and out without the need for large force.

I have a stock J30 VLSD diff that has a tight axle but it can be removed and inserted with just heavy tapping, and you can tell when the clips engage. You might have some burrs on the axles or may have crushed the clip.

Where did you get the axles, are they recently made or an old set? Maybe, no offense to Wolf Creek, the attention to detail has dropped a bit and the new ones are on the plus size side. You should have test-fit with no clips, then inserted the clips for final installation.

[malibud]

Got them new at wolf creek . I had trouble getting one past the clip. With the press I got it in. It drop until the clip fit in the grooves. I will google and see if I figure out How do you take the clips out . thanks

[beermanpete]

Did you replace the differential mount? If that fails you will get a clunk when pulling away from a stop.