Theoretically, what would happen if you had to much or to little backlash on your ring and pinion? I put a locker in recently and I was wondering if I got it right. Oh yeah, also, I understand why lockers click, but why does it pop/bang every now and then, for no apparent reason???
If you have to much backlash on the ring gear it will pre maturely wear the teath out same if you have to little. When setting up a ring and pionion you make a pattern of wear on the ring gear teeth that will chang with backlash to check get some paint and put it on a section of the then take a skrew driver and put it in between the ring gear and the case slowly turn the drive shaft to run the gear around do this a couple of times then go backwards the same number of times. check the pattern to be the same on both sides of the teeth the pattern should look like an oval half way up the tooth. The clicking sound you hear is (Itake it you have a lockright or ez locker)is the the racthit inside the locker releasing as you go around a coner. As for the loud bang it is natural as the clutch works it somtimes binds up and has to release pressure that is where you get your bang.
Too little backlash and you get accelerated ware both bearings and gears. If real tight backlash set up with cold differential when it heats up and metal expands it gets much worse.
Too much backlash less of the gear is taking the load so you make it weaker and get a different kind of accelerated ware.
Extremes in either direction can result in breakage.
In your case probably reinstalling old gears and the backlash is probably greater than when new. Should not try to tighten up the backlash but try for the same as before installing the locker with the same contact pattern. If you tighten up the back lash or change the contact area by changing pinion shims the gears could end up riding on a unworn ridge resulting in high loads in that
area, acellerated ware or braking a gear.