Part 2 1979 Triumph Spitfire 1500 Differential Removal, Opening, Repair

Part 1 Removed the differential, in part 2 I open it up to see whats clunking.This triumph Spitfire 1500 has 77,000+ miles on the engine, but unknown on the diff, I discovered it was swapped out 25 yrs ago. The Crown Wheel teeth look great, Some slight wear on the sun & planet wheel teeth, I think will not need replaced, but thrust washers will (too much end float). The right side inner drive shaft bearing was found to be the noise maker, but easily fixed. Oil seals, and carrier bearings will be replaced. The carrier shims have not worn, they were skuffed up from the refitting, just appeared to be worn, same with the pinion head spacer. Reason for NO preload on the diff (checked at the pinion nut) was to be normal break in of the pinion bearings, I was told these would start at 18 inch pounds but drop to 10, 5 or less over time ( I would remember this when setting up the new pre-loading, to set it at the upper limit so the break in period kept more torque at the end. (oops, that bit me in the butt) Some back lash to be corrected, by re-shimming carrier shim pacs. I better learn that formula for picking shims. (never did remember it, but the directions are in the book). ( editing and added more info 11 July 2015) Important Update 24 June 2020: The differential Sun gear's fiber thrust washers can fail. Copper replacement is the general agreement with some forum members about this. I am pulling my differential after about 28,000 miles to see why the gear oil has BB size fiber pieces in it.