I took an hour to finish the axle strip last night. Once the half shafts were removed the diff case could be worked out slowly. Having not seen a half shaft or diff before it was all suddenly de-mystified!
Using a flat screwdriver i tested the planet gears for play, and there was plenty of it meaning the thrust washers are warn. Replacing these is not difficult once you get to them and it makes sense to replace the sun gear washers at the same time.
In order to get the planet gears and get to the washers you need to drive out the cross pin holding them in place. The cross pin is secured with a roll pin which is peen ed over on one end. In order to remove the cross pin, the roll pin has to be driven out; its hard to find a replacement for these so care must be taken if you want to reuse it - I'm not sure if its safe to reuse it yet!
£25.00 will buy me all the replacement bearings, gaskets and washers i need to rebuild the diff and put it all back together.
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