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ICQ>
Before you go 72 kinds of crazy trying to rebuild the diff, I would remove the drive shaft and check each u-joint by rotating it in all directions. Also what is the condition of the center support collar? and the berg inside? noisy replace.
Volvo diff are very close to bullet proof, unless they have been run low on oil.
WARNING DANGER:
If you ignore a bad u-joint the results can be sectacular to say the least. I once tried to limp my 142 home with a bad front u-joint. Taking off from a stop at
10 mph it broke, actually broke it kinda a mild description of what happened, exploded might be a better word. The drive shaft was junk (had to be rebuilt) the tunnel had some very unique custom body work done by the shaft. and it BROKE the bell housing in half (boy I hate it when that happens). This was at
10 mph think about what could have happened at say 65.
Hope this helps
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