I have an issue with a Morris Cooper S MkII Gearbox I have rebuilt.
All has gone well except for the Diff Output Shafts with the Hardy Spicer coupling.
I have shimmed the diff bearings with the correct pre-load and the diff and gears all turn nicely except when I put Hardy Spicer Output couplings on with the rubber seal and washers and tighten the stepped bolts up.

When I tighten the bolts, turning the coupling gets harder and harder, more so for the side I'm tightening. (The washers are the correct thickness)
If I leave the washers off and tighten the bolts all is fine.

Any ideas guys?

have you let out the 2x colletts inside (*each side) the axles then ???

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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.

My thoughts too. These buggers fall out easy and go AWOL. And cost $$ to replace.

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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.

Do you mean have I inserted the collets inside the coupling (the C shaped collets), then yes I have inserted them.

Have you rebushed the diff side covers?
New bushes need to be bored as you would know, if you have fitted them.
If the clearance is too tight on the bush to drive flange What you are experiencing will happen.
As you tighten the bolt with the washer and rubber seal in place the drive flange kicks sideways on the spline and jams up in the bush.
More running clearance is required here than you would at first think.....
Dave

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Thanks Dave.