engine is out this afternoon. the output shaft rubber uni joints are definatley shagged and were contributing to the grinding noise i heard i am sure, but i think there is a more major issue.

i found when i removed the outpout shaft flanges from the diff that they themselves had 3mm of up and down play. looking at the diff side bearings they seem ok, but the play is coming from inside the diff.

i removed the diff assy and found that in fact when i move the shaft up and down the spider gear in the diff also moves up and down. does this mean the diff needs to be rebuilt or do i find another diff?

also the output shaft flanges have bad wear marks where the seal is supposed to seal against it. do i need to replace these flanges our have them repaired?

also the rubber uni joints have worn into the gearbox casing my about 4mm. is this an issue? or is this a commmon problem and i dont need to worry about the grovves in the casing?

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'66 BRG Morris Mini Deluxe 60HP ATW

this is the worn output shaft glange.

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'66 BRG Morris Mini Deluxe 60HP ATW

Those flanges are too worn find a better pair.
The bushes in the side covers will be worn too, get them replaced. (They need boring to fit the drive flanges after pressing in).

The slight wear in the 2 diff bushes (inside) is not usually a problem, as the output shafts are supported by the drive flanges.

I would fit a new diff pin, spider gears and thrust washers whilst it's out.
If it has the brass washers behind the side gears, keep them. They are better than the later fibre ones (which are STILL too made thick from some suppliers).

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

yeah looks like they`re the fibre type in the pics,,, but may just be mucjy oil clagg making them look like fibre

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No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.

ok so the movement in the diff output shafts is about normal?

so i really just need to replace the output flanges and have the housings rebushed?

the diff bearings seem good and there was no diff noise when it was in the car. all the wear on it seems normal i just thought that the play i found was to much, but now i see that the up and down play is supported by the poutput shaft flanges in the housing bushings.

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'66 BRG Morris Mini Deluxe 60HP ATW

Put the crown wheel in a vice. Then grab both output shafts together, turn forwards, then back. Watch the spider gears on the pin. If they rock about, they are worn.
If ignored, the pin will eventually wear through and then spear the casing, letting the oilz out and perhaps causing other damage.
Cure is to replace parts as I listed above.

Here's a VERY worn diff pin...
http://home.exetel.com.au/zoomini/zoomi ... GP1505.JPG

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

we`re a funny pair arnt we Doc---> If they rock about"... Ha!!!! of course they`re going to rock about,,, they`re going to be stuffed like every other 2nd hand diff pin in every other 2nd hand old worn out neglected early mini



I`d almost bet the diff carrier if flogged behind the thrusts too,,, but how much money & time do you spend on a 2nd hand worn out neglected std-ish early mini???

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No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.

Matt, we just pull another (better) s/h diff carrier out of the round bin, don't we.
And mod it for the tagged washers, if we can be bothered.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

On a side note, when your engine was freshly painted it would have been a wicked colour!! Very Green Goblin..

yep,,, "WE" do,,, but most others don`t have 500million mini bits all set up in labled shelves

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No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.