The springs in question are the ones behind the alignment pins correct? I don't think lighter strength springs would cause any increase in popping noises. If fact I'll bet they are a noise reduction device. You may have something else wrong, I doubt if the springs are to blame. I rarely heard any noise at all from my front Aussie locker no matter what I was doing in 4wd. Did you take the measurements needed to verify a proper installation when you put the diff together? <img src="/forums/images/graemlins/confused.gif" alt="" />