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What brand gear is this? Did you tighten everything to tork specs?
The pinion gear has to be extremely tight. I replaced my stock with a
373 ford motorsport gear. After initial installation with a 1/2'
impact it made the same noises. It was unbearable for me. I took it
to Custom Performance in Charlotte, NC. Which used to be Mark Ray
Motorsports. He used his impact with a special torquing socket and
tightened it to specs. It was completely fine after this. This could
be your problem, it might have vibration in the box itself. Try
putting a torque wrench on it. I'm not sure of the actual torque
specifications but I'm sure they're readily available somewhere.
Chris
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