First, it's actually a 2nd hand 'box, just new to me. Low-ish mileage. I have fitted a TranX LSD to it (I ground down the box casing for it to fit). I have Millers 75/90 gearbox oil recommended for LSD use. Brand new, heavy duty driveshafts.
It was initially fine with nothing seemingly wrong after about a 4 mile test drive before MOT. After that I took it for a proper run to get some fresh fuel. 18 miles later I came up to a roundabout and heard and felt a click or thump noise coming from the steering. Got fuel, checked the driveshafts were still where I left them (!) and continued warily. Drove fine, no noises otherwise, even at 80mph on a dual carriageway.
So when I got home, got underneath, checked shafts, all OK. I noticed that the gearbox was very warm though. TBH, I've not noticed in the past how warm/hot a box gets. I could't leave my hand on the diff casing, it was that warm. The gearcase was cooler but still couldn't leave my hand on it. Is this normal?
So to the other noise: Imagine if you had a very worn CV joint. It's kind of like that. I can only replicate it when you turn the steering very slightly off centre and move the car forward. Even with the engine off, pushing the car, it's as if something is catching in the gearbox. You can feel the shunt (the noise I heard) in the wheels when you move the car.
Moved the car yesterday in the drive and I couldn't recreate the symptoms. I can only guess something is getting very warm and expanding, and so catching/fouling on something. Have I ground enough of the casing? I'll try taking the diff casing off tomorrow for a look.