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Hey guys, need some help with a little issue I have been encountering, and havent really come across a answer in the search section SPECS early 260 w/ sr20det light to mild mods(stock turbo) suby 2004 3.9 lsd rebuilt 240z axles wolf creek racing axle adapters MY BACKGROUND degree in automotive science six years working for Benz as a master tech ISSUE: popping noise & vehicle hops in tight turning reverse, forward motion turning, or taking off(normal load driving) breaking u joints HISTORY About seven months ago I decided it was time to replace the stock 260z diff after blowing up its guts, After much research I picked up a 04 suby lsd off ebay used, had the diff rebuilt at known shop(seals , pinion and ring gear replaced), and installed it into my 260z using wolf creek racing axle adapters and stock 240z half shafts with new u joints. The diff was filled with motul 90pa, fluid specifically made for that diff. After being proud of my swap, it was off to testing the diff out and performed the break in procedures including the 20 or so mile drive with letting the diff cool to harden the metal. Everything seemed ok, but after 50 miles I started to notice a clunking/popping noise coming from the rear end & and the whole car would hop(during clunking noise) as if you were driving with a flat tire. This would happen when reversing down hill from my drive way and turning, or making forward turns from a stop, or when starting to move under low/normal load, or making large 180 degree freeway off ramps turns. When I inspected the diff I found the side seals leaking oil, and wondered if their was something wrong with the rebuild. I took the car back to the diff shop, who actually started yelling at me and swearing when I told them the car wasn't right and I wanted them to check it out. I asked them to inspect not just the diff, but the drivetrain for binding. Before the rebuild the shop was told to spend extra attention to the clutch's, due to the cost of replacing clutches vs just picking up a new diff. Talking with the diff shop about the problem, I asked again about the clutches, turns out they did not torque test the clutches or test the clutch adjustment, just visually looked at them and demand them ok. After a week at the shop, it was time to pick up the car. the shop said they drove the car all over and said the noise was due to no lsd additive and the wrong fluid. I showed him the suby recommended fluids and the motul site indicating that it wasn't needed, and he basically told me to GTFO and that he was perfect. Leaving the shop, heading home, within 20 miles, the diff starting popping around the corner and I lost the passenger side half shaft at the inner U-joint. The car ended up sitting for a month or two due to my schooling and work demands keeping me out of the garage. Last week I finally found time to swap the axle with a spare one I had laying around. The car seemed to drive ok for about 15 Miles, until I reversed out of a parking space making a corner....then the infamous popping noise came back. You can spin the tires free hand in the air, and you feel light resistance then a little moderate then light again, but I think thats just from the brakes(doesnt look like the axles causing it) MY THOUGHTS: I don't know if the clutches are causing the wheels to lock up and cause this issue, but that seems kinda unlikely. I am leaning more to an issue with the axles coming out of the diff at to much of a angle causing them to bind when rotating. The adapters seem to stick out a little far for my liking, but I have not seen a photo of them installed on another car to see if this distance is normal. However other people run this set up and haven't mentioned this concern. I would love to swap the axles out to cv joints, but have not found a shop that builds custom axles( I want the axle to have a suby inner to eliminate the adapters and reduce the angle), and honestly I'm pretty over spending a crap ton of money on this thing(I'm a paramedic student, poor as hell lol). I am also reluctant to spend over a grand on axles, knowing that this may not fix my issue....sooo hard to justify that one just yet. CALL TO ARMS!: This whole situation sucks, I spent days swapping the motor, and building the car, and now this issue, ugh. I'm ready to kick this car to the curb, but before my last straw breaks, I am humbly requesting assistance. Any ideas would help, any experience with this swap, any pictures of adapters installed, ect. I am located in the bay area and the only real rear end shop near me happens to be the one that told me to GTFO. I can try and get pictures or a video over the next few days if that will help anyone whos interested in this challenge.
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