'clicking' splines

[Chrisrich]

I converted from (worn out) donuts to a CV joint setup on my S4 recently. Since then I noticed clicking on clutch engagement in the lower gears. I pulled the suspension and note a very slight amount of play at the splines in the differential. If I were going to guess, it's probably on the order of .75mm. Just enough to click. Both sides have this very small amount of play, and it's clearly where this clicking is coming from.

Do you think this is nominal and not worth fussing over? They are the original splines. I remember (when I put in the CVs) thinking that they should slide out when the spring clip was removed; they did not. Should they have been removed/greased?

I'm not racing this car, and while I like to get on it, I tend to be gentle with the transitions.

Thanks in advance!

[Foxie]

Are you sure the clicking is coming from the splines ?

Are the CVs new or worn ?

When I changed the ride height on my Plus 2, the CVs started clicking. I put in a new set of CVs. On investigating the old ones, it seemed that the balls were running in a slightly new track from the original (slightly) worn track, which caused the clicking. In my opinion, they would have eventually "run in" the new track, and quietened down themselves.

I'd suggest driving with them for a while to see if they get better or worse

[Chrisrich]

Well, they're practically brand new.
I can joggle the inboard CV joint by hand (suspension off) and note a little play. I just went back and double-checked, and in fact, the movement is actually in the diff, not in the spline. I'm just not sure if that small amount of play in the differential is nominal. With both wheels lifted, the diff is allowing a slight amount of movement.
I'm just going to put it all back together and see if it abates.

chris

[Foxie]

Well, they're practically brand new.
I can joggle the inboard CV joint by hand (suspension off) and note a little play. I just went back and double-checked, and in fact, the movement is actually in the diff, not in the spline. I'm just not sure if that small amount of play in the differential is nominal. With both wheels lifted, the diff is allowing a slight amount of movement.
I'm just going to put it all back together and see if it abates.

chris

A small amount of play is normal, the spec is 0.005" - 0.007" at the crown wheel circumference.
All the diffs I've come across have been running with no problems with a lot more