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05.05.2007, 05:44 PM

Check the bottom of the main gear for burrs/deforming.

the M2 hole is made M3, and the hole is countersunk again, which takes a lot of pressure because of the hardness of the steel. This might have deformed the material slightly causing it to bind at every turn. (in other words, the gear isn't flush with the case) perhaps there are burs on the cup itself?

or is the problem inner gear related? In this case; check if the pin that holds the two floating gears is loose in the case, with some of the diffs you need to dremel a round spot to the end of the small shaft that holds these two floating gears.

You did cross-tightened the screws?
   
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