Ok, so I have had rear end noise ever since I picked the car up from the previous owner. Now at first it was only on right hand turns. I have the Torsen option and a M6, now I noticed the rear was leaking a little so I opened it up and it was really low of fluid. So I filled it up. After that it was ok driving straight just would really make a sort of grinding/drill noise.
Now I have pulled the whole thing apart and well I'm totally stumped...
I have found no evidence of anything that could make the above noise. Could the worm gears inside the torsen be making these noises?
Please see pics in link below
https://plus.google.com/photos/10500...52739926410001

The C-Clips I can barley feel the wear with my nail. The bearings all looked good, the ones I could see(didn't get to the pinion yet)no bluing or chips ect... I did not see any nicks or chips any were on the ring. The only marks I could see were in the torsen (please see pics) I did notice the left tube appears to not be perfectly straight, but I'm not sure might just be the angle and how its jacked up.

I'm pretty frustrated at this point I don't want to order a bunch of parts that are unwarranted.

*UPDATE* Fixed the noise

 

the car did have a vibration above 45-50 or so. I fixed that with a drive shaft R2. Could this maybe messed the pinion bearing up? That is the step I am at right now.

 

If the noise is only made around turns it is either one of the following: A) the differential or B) the main differential bearings. The reason is because the loading on these parts changes in such a away that noises could appear when turning, if there is a problem. The main differential bearings (B) could be the culprit since (if I am interpreting your pics correctly) it appears there is pitting on the bearing cup. Since they are one of the less expensive parts, it may not be a bad place to start.

 

thanks, i read the front bearings go out pretty fast and with the front seal leaking as fast as the show room floor mixed with an unbalanced drive shaft.
This is where i will start, a quick bearing swap. Funny thing is the cost of all the tools and parts is cheaper than to have someone do it here on the island.

 

If you are buying the bearings I would recommend richmonds kit that can be found on summitracing. It included Timken bearings when I bought it a few years ago (probably a good idea to verify though). Many of the low cost kits now a days include knock-off chinese bearings that may look the same but at the microscopic level they are not and you will find yourself doing this job again unless you purchase a quality bearing.

 

thats the kit I picked up, hope it does come with the quality bearings.

 

kit came with Federal bearings. doing futher research I found both timken and federal have factories in china. "Joint ventures"
So I guess if there is no USA on the bearing its not MERICA made... lol
anyway the bearings I am replacing are timken usa.

 

Did the problem fix its self once you put shoes on?

Always wear shoes when in the garage.

 

The problem was the missing spacer.

Shoes... lol I only wear my shoes in the garage any where else I were flip flops...