It took me well over 2 hours to remove the cross pin which holds the roll pin in place. i had to drill out the peening holding the pin in and drive the pin out with a 1/8" parallel drift, which ended up bent! I also had to remove both the bearing retainers to get a clean line on the pin. This is risky as the crown and pinion mesh i accuratley set and not easily reset when disturbed! Hopefuly i kept it good!
With the pin out, the roll pin drifted out smoothly and was in great condition. I .
was then able to walk the planet gears out along with their washers. The old brass thrust washers were very warn and had a sever lip and were substantially thinner than the new. The picture shows old left and new right thrust washersThe sun gears cam out easily with nothing in their way. There was only one thrust
washer on one side! The other had either completely warn away or was not installed originally! I placed new Tufnol washers on the sun gears and put them back in the diff.Inserting the planet gears with new washer is much more difficult! Because all the new washers are so much thicker
than the warn old ones, there is no play or movement to get the gears in. Both planet gears have to be inserted at the same time, from opposite sides of the diff. It took me another two hours, but with both planet gears part meshed and their washers tucked in a little further, i inserted one half shaft and gave it hard twist...bingo! Both gears rotated in and lined up. The washers needed a little encouragement into position.
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