New KAAZ 2-way installed: problems, please help!

[cj]

Okey guys, i had problems with my diff ever since i bought the car. i've rebuilt it a couple of times and spent a lot of money until i finally bought myself a brand new Kaaz 2-way lsd (zenki).



This time i decided to perform everything stricktly stricktly by the book. I replaced all bearings with koyo new ones, inspected the pinion and crown, inspected the halfshafts and replaced their bearings also. I prepared Motul 90PA as gear oil since we don't have KAAZ oil in Bulgaria.

The car was assembled. According to the KAAZ tech manual i'm supposed to perform a special breaking procedure. This basically means 30 minutes of driving in 8-line (eight line) at very low speed with the clutch in while doing the U-turns and the acceleration applied in the straight section.


More detailed info: http://www.kaazusa.com/techHelp/tech_Help.htm

So i went out to a big parking lot and started driving. From the very beginning i noticed some chattering noises while turning, but those were described as normal in the KAAZ manual. I had my 30 minutes of practice with a short interuption by the police at the 15th minute Everything was looking good. I decided to try a couple of slides before going back to garage to change the oil. Drifting test also seemed successful. I headed back to the service shop and not long after, the following problem occured: Noticable only while turning (doesn't matter if in gear or not) i hear vibrations and clicking noises. The car has power to the wheels when turning so it's not broken halfshafts. I reached the service shop and we performed the following test: we lifted up one rear tire and tried to spin it by hand when not in gear. Then we tried the same with the other rear tire. Both tests were succesful, meaning that, altough with difficulties we were able to spin each tire, while the other was still on the ground. The interesting thing is that the mechanics told me they have tried the same procedure before i took the car out and at that time they could not rotate the tires. I don't know if this test leads to a certain conclusion, but decided to share it with you.

The mechanics called me this morning. They have taken out the halfshafts and they look good. This means that the problem should be further inside. I don't want to open the brand new KAAZ unit yet.

So anyone that have experience with similar units or installs, please, share your opinions!

Thanks guys!