Its all good, no worries man. I appreciate you bothering to back and forth with me. I'm repealing them now .Gonna go overnight this time. Service manual says 20 minutes. Fighting a migraine setting in. Gonna walk away from it today. I'll post up when I get it all back together. Thanks again.

 

The way it's shown with the red, the convex side is away from the gear. You would have to flip it to have the convex side against the gear. Like your picture with the green line.

 

Thanks again guys. Painful. I put it together after soaking the packs overnight in the friction modifier slop and put it together today convex side against gear back and am to the point where I have center pin in and non ring gear side bearing 99% on. Trying to find the right socket size or other idea to seat it the rest of the way without bunging the **** out of the outer bearing roller pin cage. Ive talked to enough people now that have said its been pretty freaking tight when they had it all together but it worked out in the end just fine. Makes sense i guess with everything being brand new and original thicknesses. It is a clutch pack made to lock up....Never done a backlash before and have to make the bearing race adjust cup tool tomorrow at some point. Everyone said differentials were terrifying and a nightmare to get right. Guess were gonna see.
**** it Dude. Lets go bowling.

 

Soooooo...any noise is bad.... Took it for a spin around the property. Nothing crazy, just some putting around some figure eights and a little forwards backwards. Nothing over 30 km/h heard what sounded like a metallic clinking. No pattern to it and very very sporadic. Hardly happened but when it did it sounded crappy.
Back on blocks, diff cover off and nothing has changed. No metal bits, retainer clips in place still, Backlash still 0.007 / 0.008. Not brake noise.
Flushed the diff and threw the cover back on. Filled it up, this time adding a lucas diff additive, on top of the friction modifier and Lucas 80 90 diff fluid to full. Ran it around again and same same. Not rotational, no pattern to it. Hear it for a second or three and then its gone. Doesnt happen when i take my foot off gas and coast, doesn't always happen in just forward or just reverse. Not speed related either. Im F*****g lost here.
No damage at all in the diff.
Any opinions or advice?

 

When I did my side bearings I used the old bearing as a tool to press it on the rest of the way. Describe the sound to me the best you can.