Part2 - The rebuild

Well, day 2 and I start again. I got the old bearings off the diff shaft. Ideally you need a three leg puller for this. Hammer the new bearings on the diff using a large socket, as not to put any pressure on the outer ring of the bearing. Making sure its fully home. (pictures 4 & 5) At this point with the empty casing, I cleaned both matting surfaces with a scraper and a fine wire brush and finished off with emery paper.

Next I fitted the diff complete with the new bearings into the casing, then slotted the gears complete back into the casing, making sure that the selector rods where sitting in the base. Next the selector and reverse mechanism (8,9,10,11), then the reserve idler gear. I used thread lock on all the bolts that I put back in. Pictures 12 & 13, the case is ready to go back on.

1 - Plastic speedo ring	2 - Plastic speedo ring 2	3 - Diff with old bearing	4 - Diff with new bearing	5 - Other side of diff with new bearing
6 - Empty gearbox casing	7 - The gears taken out complete	8 - Close up of the internals to make sure i got everything back right	9 - Reverse gear selector	10 - Reverse idler gear
11 - Gear selector mechanism	12 - Back together.......	13 - Ready for case to be put back on....

See part 3....