Later 2000 to 2006 diffs do fit early axles.

[Ken B]

Just so everyone knows, the later rear loading diffs fitted to 2000 to 2006 axles(not Dana type) do fit into the earlier Mk1/2/3 casings. I bought an axle via Luke on here, and after careful measuring and double checking could see no reason for it not to fit. I used my Mk1 crownwheel carrier rather than the newer one and just transferred the lot over. The only problem I had to overcome was the pinion flange. This uses bigger diameter splines meaning the mk1 flange doesn't fit. So I machined the Mk6 to match the dimensions of my Mk1 flange and re drilled it, thus saving on problem mating the prop. The pinion seal is exactly the same dimensionally for both axles too.

The axle the Crownwheel and pinion came from.


My Mk1 Casing with re machined and re drilled pinion.


any questions please ask.

[montym100]

Thats good to know, will this also fit the early Mk1 ie the square axle?

[Ken B]

No cos thats a different type axle all together. They load from the front not the rear, and use a smaller crownwheel and pinion dimensionally.


I should also mention that I had to buy a cheap tap from ebay to thread the new holes. M10 x1.0 thats not a standard thread pitch, but the tap only cost £7.

I can re-machine and tap the pinions for anyone else, if you want to do the same.

[Luke]

result

[consul-ute]

So does this mean theres more ratios avaiable?If so whats the highest gearing?

[robbie.cee]

Bloody good work!!

[Luke]

So does this mean theres more ratios avaiable?If so whats the highest gearing?

not sure if the 4.27 is the same axle - i'm pritty sure the 3.77 is different 5.14 and 4.63's are the most common in mk6's and they are the same ratios all ready available

[Ken B]

Think those ratios dont fit as Luke has said. Are they not from the early Dana axles ? When I spoke to Abbey T they said the only ratio they could get were 5.14 and 4.63 for my type axle.

I re fitted the axle yesterday, just trying to find some correct grade oil to go in it now.

[DougT]

Fantastic work Ken, many thanks.

So see if I have this straight. To change ratio in an Mk1 diff using Mk6 parts, you need Mk6 CW&P plus Mk6 pinion flange and that's all ?

Have I got it straight ?

Thanks

Doug

[Ken B]

Fantastic work Ken, many thanks.

So see if I have this straight. To change ratio in an Mk1 diff using Mk6 parts, you need Mk6 CW&P plus Mk6 pinion flange and that's all ?

Have I got it straight ?

Thanks

Doug

Doug, yes that is about the size of it. If you are using a diff from another casing, then it is important you keep any spacers that are fitted between the pinion rearmost bearing and the teeth. There is normally a thin spacer in there. It is this that positions the pinion in correct alignment with the crown wheel in the fore and aft plane. Obviously then you will need to adjust any play ( left to right) of the crown wheel using the adjusters on the CW carrier. Dont forget to use a new crush spacer as well.

If you are using a brand new CWP set and a different ratio to what you had, you are going to have to set this up from scratch. The spacer I mentioned on the pinion behind the rearmost bearing does alter in thickness depending on which diff ratio you have.

The bottom line was I had all the bearings from 3 different pinion shafts, and measuring with a micrometer, I found no measurable difference between any of the bearings. I then checked two useable pinion shafts, no difference there either apart from the overall diameter of the teeth( they were different ratios). I think its fair to say, the engineering used in the making of these diffs is quite consistent so is not the scary thing to set them up its made out to be.

Yes you will need to use the mk6 pinion with a mk6 CWP. The splines are larger dia than a MK1/2.

My CWP came from mk6 axle via Luke who assured me it was silent. I used the bearings from my original 5:8 ratio as they have covered only a few miles. I drove mine about 20 miles tonight and it is totally silent. Thanks Luke!!

[Luke]

My CWP came from mk6 axle via Luke who assured me it was silent. I used the bearings from my original 5:8 ratio as they have covered only a few miles. I drove mine about 20 miles tonight and it is totally silent. Thanks Luke!!

just glad you put it together right or my name would have been mud

[Ken B]

Mate i had more trouble locating the correct oil in this godforsaken town than I did re assembling your diff!!! But honestly mate, I don't know how many miles it has done, but there was hardly any wear on it at all, nor the bearings.

[Trinny]

I have a slack pinion seal and have to keep topping the diff up.
I had the same trouble getting some thick oil which stays in longer,
a mate gave me some 140 grade (used in some old Burman motorcycle gearboxes) but that ran out (no pun intended)
I managed to find an new old stock container of 85/140 at an oil supply depot
so I'm using that for now.

[Ken B]

Why not change the seal then? Just mark pinion nut, count the turns needed to remove it, change seal change crush washer, then do it back up the same number of turns using Locktite. Done Ford Anglia leaking diffs the same way loads of times. You're not changing anything as log as you do the nut up the same turns.

I got my oil from an Agricultural supplies in the end. Local motor factors and the local Ford place were useless.

[Ken B]

Just a couple more photos. Seems to be ok so far, done a fair bit of running around. Off to Waddington tomorrow round trip of 90 miles. Hopefully nothing will drop off!!