So, I broke an axle just before parking the car for the winter, and I thought the diff was crushed as well. I removed the diff from the car, and opened it up today (expecting pieces of ring and pinion gear to fall out). To my surprise the gears look just fine! But, the diff is harder to turn around than my spare diff. It feels like turns smoothly, but it takes a bit more effort. Any ideas what could be the reason for that/problem?
All help appreciated!

 

When you say "crushed" was the axle broke due to impact?
Turn the input flange a little at a time then rock the ring gear back and forth to check for backlash. The ring and pinion should have a bit of a gap between them.

 

No, the axle broke with 3rd gear wheelspin (from the tires getting grip I assume?). I expected the gears of the diff to be "crushed" into bits and pieces as I broke a diff about a year ago, with this result:







I expected the same now, but I cant find any visible damage. I tried looking at the gears in the Torsen unit itself, but couldn't see any obvious damage there either.

Edit: The car is turbo'ed and at ~490-500whp, btw.

 

Perform the test to check for backlash. When you turn the rear does it feel ruff or just tight?
Put a stub axle in to see if the LSD turns free and smooth.

 

Just tried this, and yes, there a little gap between them. See video

http://s5.photobucket.com/user/cmnye...6b84d.mp4.html

When I turn it feels just like something is tight, not ruff. Maybe a bearing?

 

You need to check all the way around the gear to be sure there is a gap in every place you stop to check. Do you know how to reset the ring gear/LSD if you remove it? If you can remove the carrier you can turn the pinion without interference to see if the issue is there.

 

I'll check all the way around. I don't know how to reset the gear if removed.. Is it described in the Honda workshop manual?

 

I was just out in the garage again to check, and there is a gap all around.

 

How tight is it, do you have a inch pound torque wrench to check the bearing load on the input flange?

 

This is how to check the load, with the ring gear in place it should be around 12 to 20 inch pounds
I posted a pic to try to show you how to check the load