More on Diffs

So, when last I wrote, I just had to find the right bushes for the diff and then get it in. That was in 2 months ago. In that time I have tried two sets of bushes and still not too sure I have the correct ones. They are Triumph TR6 rear inner suspension mounts. The picture below shows how the old ones protrude slightly front and rear:

The ones I removed were 1" diameter and 1 3/4" long. The first set I got were slightly too short and fitted front to back exactly. I took those out again and fitted slightly larger ones, which have the correct tube length, but once installed the rubber protrudes a little more that he originals.

On top of this, looking at a few images on the web (- unbelievable I know but I know of 3 or 4 images on the web of Series one diffs!!) some of them have the bushes not protruding at all....anyway. I am leaving it as is for the moment. More later.

So, I got the diff mounts all sorted and installed the diff, which is not at all an easy job!

Its not immediately obvious from the picture, but the diff is tilted. It took a fair bit of giggling to get it to fit at all. Looking at the top mount you can see that fitting the diff in place causes it to bow:

In fact the top mount of the diff casting is about 3/8" below where it needs to be to fit properly:

And what's more the top mount appears to have been cut way off centre in the factory:

Which drags the diff over to the side when the top mount is bolted up. Solution.....

Make a new top mounting bracket, and use some alloy spacers, which is where I am at the moment.

I did make progress in other areas in the last two months.

The drive shafts were a bit odd. One was completed rusted and not savable, although one of the flanges was fine, so I had to saw that off. Interestingly the universal joint cups had been brazed into place. I wonder why? Paranoia?

The other drive shaft was fine, or at least so I thought. I bought 1 new drive shaft and a new drive flange and then set about sorting out new U.J.s.

First drive shaft went together fine, but the original shaft appeared to be different to the other. It had a more robust collar and the arms were farther apart. To cut a long story short, it took me an age to find U.J.s that fitted this shaft. They were a special size that was difficult to find and cost a fortune. Ultimately it worked out only slightly more expensive to buy a complete new shaft, new U.J.s and two new flanges (yes, the flanges were a different size too) than to buy and ship the UJs. So, now I have a complete set of new shafts. The only part remaining from the old set up is one flange!!.