Two things to suggest...
Number 1:
- This is unlikely to be anything to do with the ATB internals, as the helical gear sets do not rotate on their own axis at high speeds. With the vehicle moving in a straight line they would barely rotate at all inside their pockets. (Both the pockets and the helical gears, the whole diff centre, would be rotating on the same axis as the crownwheel, but no real movement of the helical gears relative to their pockets)
Number 2:
- I bought two Ashcroft ATB's for front/rear of my 2013 TDCi (Puma) 110 a couple of years ago. Bought two recon diffs from Ashcroft at the same time, and had Ashcrofts assemble with the new ATBs with all new bearings etc for me as I didn't trust anyone locally (Malaysia) to do the job.
- from new I had some noises similar to what you mentioned, getting worse after several hundred km
- on checking (pulled the diff) found that there was a fair bit of runout measured at the crown wheel
- seems on some diffs there is a possibility of interference between the crownwheel and ATB. Had to chamfer off a bit...
- solved the issues. Ashcrofts came to the party covering my costs to rectify (since they had assembled the diff/ATB originally)


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