i have had this with mine, eventually i just gave up and ran them anyway. they shut up after a while, but i did eventually strip them. not sure if that was purely down to my 18 engine, but after stripping a few i went to the hardened sets - pricey, but still alive after 2 years...

im sorry mate, i dunno what else to suggest.

mine seemed to have a kinda high spot on the large 43t diff gear, i could feel it as i turned the wheels, but couldnt see anything wrong after i stripped it - is urs the same?