LSD output circlip

[wantafaster1]

It's only happened a couple of times, but that's still too much!

Circlip comes off and the drive slides out of the diff. Is there a fix, or what conditions are causing it to happen?

[Jason]

Do you have the retaining washer in place between the circlip and output cover(c-bta1243).

[wantafaster1]

Didn't personally build it, but I'd be very confident that it's done right knowing the man who did it.

We're probably on the same page though, I was wondering if the clip snagged and then opened momentarily and flicked off.
But, under what particular conditions does it happen? Rally car, so it seems to take off and land lots, no issues, or 3rd gear say, big corner, flat out and spinning and gripping, no issues. Yesterday is the second time in maybe 7 years.

[Jason]

Have seen some with the shaft worn on the running journal that slightly reduces the depth of the groove for the circlip. Worth removing and inspecting to check. Without the washer fitted the strengthening webs on the inside of the output cover will ping the circlip off.
Another possibility is the bush in the side cover is worn.
Worth replacing the circlips if you do remove to inspect

[Spider]

In general, circlips can dislodge for a number of reasons;-

Fitted the wrong way around. They are usually made by stamping and have a round edged side and a sharp side. Sharp side is always to the outside.
Tapered groove is another.
What it is they are butting up against on the OD isn't flat.
In this case, a worn shaft or bearings, allowing the shaft to tilt.

In some applications, I fit them with a drop of Loctite for insurance.

[Oneball]

It’d be worth checking your drive shaft isn’t running out of movement or sticking when the suspension goes through its full range of motion and steering lock.

[SPO41]

Was there a thrust washer between the circlip and the alloy housing?

[wantafaster1]

Yes washer in place