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(Hopefully) end of story. The diff got pretty gritty again. I think I was still running it too loose. I finally bit the bullet and bought an entirely new diff. New gear, new AE carbide balls, new thrust balls/washers, new drive rings. Could've bought some ceramic balls for similar money, but I bought into AE's marketing hype about their tolerances being higher. Who knows? After rebuilding it pretty carefully, and using the piano wire, I tightened it until I ABSOLUTELY could not get it to move. It's smoother than I've ever gotten it to go before.

Thanks for all the help again!

Well, you need to check the adjustment frequently when you use new parts. The parts will wear in or "seat" very quickly. This means that for the first run, and a few successive runs you need to check for slipping. after a handfull of runs though, the diff should be seated, and should last a long time between rebuilds. -Jeff