I recently rebuilt my 8.8 IRS differential and ever since I put everything back on the car I get a nasty sounding "pop/clunk/grind" noise coming from either the transmission or the rear end. It happens when I've left my Cobra parked in my garage and left in gear (usually left in 4th) for a few days. As soon as I put the car in gear and begin to drive it out of the garage, it hesitates for a minute as if something is holdin it back, like I'm pressing on the brakes, then finally releases with a nasty sounding clunk or pop. It sounds like it's coming from the rear end mostly. I rebuilt everything to Ford spec using the IRS rebuild guide, so the backlast and preload is all correct. Only thing I used that wasn't a FRPP part was a Ratech "smart sleeve" instead of the crush collar. Once I'm driving, and I park it at the store etc. and get back in it to drive, it acts fine, no noise or grinding. I put about 1.5 bottles of fluid in the rear. It never poured out of the full plug (factory cover) because I didn't want to overfill it and have it blow out of the vent tube. Any ideas what's up? Did I not put enough fluid in the rear and maybe with it sitting for a while the ring and pinion gets dry from runoff and causing it to do this due to lack of lube? Just throwing this out there.
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