On leaving the office it sounded like a tractor with a straight cut gearbox, I was amazed it made it home. Upon removing the diff (Diff bolts to PPF were tight, everything else came off easily) and examining it, a tooth was missing from the pinion gear, which I found at the bottom of the casing. Everything else seemed ok, but obviously this wont happen on its own. I suspect bearings have worn out allowing too much lash.
At first, couldn't find anything broken until slowly rotating it around i noticed the missing tooth. Nothing obvious had fallen out when i drained the oil, but a scrape around the bottom of the housing revealed the missing tooth:
There was no other broken bits I could see. I got a new diff from Autolink in the UK, its a 1.6 viscous LSD, it works well and is more predictible than the torsen, but with much less power on oversteer at the loss of grip of course. I now find the inside wheel spins quite a lot when exiting tight corners hard whereas before i would get the full power down or slide gently out. Its completely silent though, no clunking so far which is a big bonus.
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