Updated: G50 Help
 

Well, I may have pulled a good one.....

I removed the axle flanges per the Bentley (one at a time) to do the seals.

I re-installed the axle flanges and tested them by turning and watching them spin opposite each other and felt a mild "pop" in the diff while turning.

I then tested by turning the input shaft. After a few degrees of rotation, I heard a loud "clang" and it stopped turning. I turned the other direction and it would make one complete revolution and "clang" then stop again.

I pulled the flanges again and inspected the flange end and diff end. I found tool markings on each side that appeared to be alignment marks. I aligned the flanges with diff marks and now it spins without interruption. However, I can feel the mild "pop" while spinning either freely or through the input shaft.... This does surface with the flanges spinning freely or locked while spinning the input shaft

The Bentley manual mentions doing the flanges "one at a time to avoid difficulties aligning the drive flange splines".

Is the problem I'm seeing a drive spline alignment issue? If so, how does one align the splines so it spins freely?

Thanks in advance.

PS: The trans in on the bench so it is easy to work on.

Hmmm......

The problem is not in the differential. It spins quietly.

The soft "clunk" or notchiness is coming from the input shaft.

Problem description: When I spin the input shaft by hand in neutral, there is no clunk...... When I spin the input shaft by hand with the trans in gear (any gear), I get a "clunk" and a solid notchy feedback with frequency consistent with the gear. For instance, if the trans is in 4th gear, the clunk appears approx. once per revolution on the input shaft.
I can spin the output shafts and get the same "clunk" and notch.

This doesn't seem normal but I would like some expert opinions.... Thoughts?

I don't have an answer to your question, but am just curious about this one, so here's a free BUMP!