Bad grinding noise in rebuild 01E transmission

[Sindre]

Hi.
I have just rebuild my 01e dsy transmission with new syncros and 1-2 shift collar.
And now when its back in the car i have a bad grinding sound in it.
The car is in the air and the propshaft is connected but not the front driveshafts.
There is no grinding when it is in neutral and it shifts fine tru all gears.
Must the front drive shafts be mounted to test the gearbox when the car is hanging in the air?
Or might i have a bearing failure/gears not in right place?
Has anyone been facing a similar problem?
Clip of the sound: https://youtu.be/2qrHw4doyvM

[Scotty@Advanced]

Something isn't right, sounds like it was put together wrong or not installed correctly.

[neilthewheel]

Ya, something funny. Bearing got hurt from being pressed on wrong, or maybe some of the tapered rollers in the hollow shaft backward? I dont know if it will even go together like this, but those things dont have a ton of taper to them and prob easy to get flipped.

Diffs will make noise if everything isnt spinning the same speed, but hard to quantify. Its a ton of work to get back into that thing so might be worth the effort to put the front axles on, or take the driveshaft out to get everything even steven just to check.

I think Scotty has one or two of these things under his belt , so what he is saying is unfortunately prob gonna be correct.

[Lanorg]

I don't know if the axle shafts being on will change anything. The center diff (if stock) is 50/50 so it's going to send half the torque to the front regardless. Having less weight to twist isn't going to make a grinding noise.

Is there oil in it? Also, I assume reverse does the same. In your 3rd and 4th gear tests, the noise was different depending on the speed, so that might indicate the grinding coming from the output shaft cluster or center diff. Considering the noise is not present when the input shaft is spinning, one could assume that the bearings are fine and that the problem lies further down the line when gears become engaged.

Be wise and take it apart and confirm each part comes out like it does in the video that JHM sent you to follow. As soon as you come across the part that doesn't, you'll know what the issue was. Keep us posted.

[zillarob]

Our diffs will send 100% to the easiest corner to turn if unloaded.
They need all 4 tires on the ground with some resistance to make the magic happen.

[Sindre]

I have dismantled the gearbox. I can't find any obvious problem. All bearings looks fine.
How much axial play is there suppoused to be on the input schaft when torsen housing is removed?
And how much axial play on the biggest gear on output schaft?

[Sindre]

So I pulled the box apart and couldn't find any fault with the gears or the bearings. Only some scoring on the wormgear in the center differential.
Assembled the gearbox and made me a tool so I could run the gearbox outside the car.
When I locked the rear output flange there was noise in the differential, little to non when not locked.
So when the diff sends power to front/rear axels the wormgear turn and sounds terrible.
The car is now put together and works just fine.
No noises from the gearbox during normal driving.