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Diff reassembly
https://www.ausmini.com/forums/viewtopic.php?f=2&t=53882
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Author:  Drekkus [ Tue Jun 02, 2009 6:25 pm ]
Post subject:  Diff reassembly

I'm up to reassembling the diff.New planet gears, comp diff pin, washers, bearings.Spins nicely until I tighten up the crown wheel to the cage to specs.Then it doesn't move.
I take it thats not right and my new washers are a bit too thick.I'm using brass washers instead of the fibre ones.So go back to fibre or can I thin out the brass ones or is there something else.?

Author:  Wombat [ Tue Jun 02, 2009 6:46 pm ]
Post subject: 

Thin fibre ones out of an early MK1 diff is the way to go :wink:

My bad :oops: It is the thin brass ones out of an early MK1 - I had to use them as the new fibre ones were way too thick - lucky I had an old MK1 diff here and I pulled them out and used them

Author:  drmini in aust [ Tue Jun 02, 2009 7:09 pm ]
Post subject: 

Brass ones are better than fibre. They don't fall apart with dirty oil. :lol:
The fibre washers they sell now are too thick and by your problem new brass ones are too.
One way to use them is get a few thou surface ground off the centre hexagonal spacer.
Last diff I did needed .008" off (.004" off each side). You just grind 2 opposite faces, put these towards the side gears.

<edit> you need to do a trial assemble with 1 washer missing, then use feeler gauges to measure to the spacer see what the remaining gap is.
Then compare that to spacer thickness.
You only want about .003"-.005" total clearance.

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