A bit late to the party, but my solution has always been to toss the entire thing and replace it with a limited slip from a wrecking yard.

The difficult part is locating a limited slip, but swapping out the unit is routinely a one hour job.

From Post #33; "I am thinking on dumping the whole Gear issue and getting a Limited slip Differential Carrier but have not done the parts survey on that."
I have been thinking about that also.
But, I read that some People like to burn Rubber and it uses up the limited Slip Differential fast. Maybe that would not happen Van.

What I really need are 2 good Side Gears.

I am also left with a free Spider Gear Kit that does not fit. If I can find a way to remove some metal from the back of the little Spider Gears I believe I could use the Kit. The bugger is the back of the Gears are hemispherical. I can't think of an accurate way to remove the Metal.

I could also gain Clearance by facing off (I have a Lathe) the Side Gear where it mates with the Carrier; where the thrust Washer Goes but that would move the Gears away and make the C-washer lock not as good and the Axle would have more in and out play.

Unlucky for me the Aftermarket company made the shape of the Gear Teeth on their Side Gears different so I cannot just use the old small Spider Gears.

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84 300D, 82 Volvo 244Gl Diesel