MOT Failure would be an understatement

[MrShuffle]

Sorry for the late reply... Quick update: bought a casing but it didn't fit. It wouldn't connect the diff to the shaft? Currently its 30 miles away at a garage near to my parents (set my dad on as project manager). I'm now on the hunt for a complete rear axle. Don't suppose anyone has one lying around?!

[Jordi]

Why wouldn’t it connect the diff to the prop?

[MrShuffle]

Apparently the diff housing on the casing I'd bought was a different diameter to the housing that was connected to the shaft so I've been told...

[Jordi]

That is very possible there is a large flange with M10 bolts and a small flange with M8 bolts.

Very easily solved.

Swap the diff between them.

Swap the flanges but that means ensuring you set the diff right again.

Swap the end of the prop flange.

[ScottieJ]

Can you post up some photos?

I'm not 100% sure what you mean in your last post.

So your diff doesn't fit your new axle case? if it's too small for the new axle case then its a 413 case (not Samurai)

or

Your propshaft doesnt bolt up to the new diff pinion because it has a different flange size.

On the 410 there's also 2 different sizes.

Early 410 with skinny propshafts have a smaller flange pattern again, smaller than the common 410/413/samurai 56x56mm (8mm bolts)

If you can post up some pics I can help yo sourse the correct axle for your 410. I might even have one.

[Jordi]

I forgot the 410 bit. Apologies slightly more vehicle specific than 413 / Samurai bits.

Scottie will keep you right on it though

[Anton]

So your diff doesn't fit your new axle case? if it's too small for the new axle case then its a 413 case (not Samurai)

Do you mean "then its a 413 case (not Samurai)" or do you mean "then its a 410 case (not Samurai)"

I was under the impression that 413 and Samurai diffs were different ratios, but identical in size/bolt pattern unless the Sammy is very late model?

The 410 and LJ were smaller diffs? Or do I have all my wires crossed up?

[Jordi]

Sounds like its a samurai / 413 housing but his is a 410.

[Anton]

I'm tired. I'm brainfogged. I'll leave you guys to it - I'm sure Scottie knows what he's talking about, I'm just easily confused at the moment.

[MrShuffle]

Your propshaft doesnt bolt up to the new diff pinion because it has a different flange size.

On the 410 there's also 2 different sizes.

Early 410 with skinny propshafts have a smaller flange pattern again, smaller than the common 410/413/samurai 56x56mm (8mm bolts)

That one I think. From what I gather everything fitted in the case fine, but when it came to bolting up, the prop didn't match up to the casing because the casing around where the diff gearing goes is larger.

Picturewise I'm stuck really because the casing has been taken off the car as I was planning on returning it and starting the search again... haven't got time atm so it's been done by a mechanic through my parents (ultimate outsourcing or what?!)

Mines an 1985 410 although I dont have anything to compare it to it's my first SJ.