DougT wrote: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 ?
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!!